Interior Wall Construction

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application corresponds to a prior U.S. national application entitled, "Interior Wall Construction," filed May 29, 2007, and having attorney docket number 1006.U03, which claims priority to U.S. Provisional Patent Application No. 60/809,627, filed May 30, 2006, entitled, "Interior Wall System," which is incorporated herein by reference. In addition, the present application is related to three co-pending PCT International Applications also filed May 30, 2007: "Exterior Wall Construction," attorney docket no. 1006.N02; "Column and Beam Construction," attorney docket no. 1006.N04; and "Floor and Roof Construction," attorney docket no. 1006.N05.

TECHNICAL FIELD

[0002] Embodiments of the present invention relate generally to construction materials. More particularly, embodiments of the present invention relate to construction using foam materials.

BACKGROUND ART

[0003] Polystyrene, a polymer discovered in the nineteenth century, is a highly useful material having a wide variety of applications that is manufactured for use in numerous commercial enterprises. One of the most common uses of polystyrene, however, is expanded polystyrene, which is used for making such products as packing material, craft and model materials, and take-away food cups and containers. [0004] In addition to these uses, expanded polystyrene is one of several foams used in making insulated panel building materials. These building materials, also referred to as insulated concrete forms, are used to form molds for use in constructing walls of buildings. Most commonly, an insulated concrete form for a portion of wall is set in place and the concrete is then poured into the insulated concrete form. The form then remains in place, where it acts as insulation both for curing the concrete and as general insulation for the building or structure being constructed. [0005] Using foams for building construction provides numerous benefits. For example, foams serve as excellent insulators helping to reduce energy costs. Foams also provide superior sound absorption and their use contributes to fast construction of

buildings, thereby creating competitive costs for using foams when compared to conventional building methods such as wood framing. These benefits have led to increased use of foams in building certain portions of buildings, such as exterior walls built using insulated concrete forms.

[0006] Although foams are used extensively in manufacturing insulated concrete forms for exterior walls of buildings and other structures, use of foams for other building systems and materials is not widespread. What is needed are systems and methods for configuring expanded polystyrene for interior walls of buildings and other structures.

DISCLOSURE OF INVENTION

[0007] Embodiments of the present invention include an interior wall system including wall panels made of foam material, such as, for example, expanded polystyrene. In one embodiment of the invention, the wall panels are configured to be interlocking. Moreover, the wall panels may be configured to create a wall having any length, width, height, and shape. The wall system is also characterized by the use of wall studs to hold wall panels in place and to provide increased stability and security of the wall panels. Thus, innovative systems and methods for using foam forms in buildings are introduced by embodiments of the present invention that use foam forms for interior walls, rather than exterior walls.

[0008] These and other aspects of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.

BRIEF DESCRIPTION OF DRAWINGS

[0009] To fUrther clarify the above and other aspects of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The drawings are not drawn to scale. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which: [00101 Figure 1 shows a wall panel; and [0011] Figure 2 shows an interior wall system.

MODES FOR CARRYING OUT THE INVENTION

[0012] Embodiments of the present invention relate to systems and methods for interior walls made of foam materials, such as, for example, expanded polystyrene ("EPS") material. The insulating interior wall system of the present invention, and methods of making the same, provide a lightweight to heavyweight structural design incorporating steel stud gauges and foam wall panels. Embodiments of the present invention thus provide a high standard of sound insulation for an interior wall and are designed and configured to accept any number of finishes, including, but not limited to, plaster and drywall.

[0013] With attention now to Figure 1, a wall panel 100 of an interior wall system is shown. In. one embodiment of the invention wall panel 100 may be configured of any foam material, such as, for example, EPS-cement composites, polystyrene foams such as expanded polystyrene and extruded polystyrene, and polyurethanes. [0014] In addition, wall panel 100 includes top 102 and bottom 104, as well as first end 106 and second end 108. First end 106 includes receiving portion 110, while second end 108 includes protruding portion 112. In one embodiment of the invention receiving portion 110 is a groove extending along the height, A, of wall panel 100. Similarly, in one embodiment of the invention protruding portion 112 is a protrusion extending along the height A of wall panel 100.

[0015] In one embodiment of the invention where multiple wall panels are configured in an arrangement to create an interior wall having any length, width, height, and shape, receiving portion 110 of first end 106 may receive a protruding portion of a second wall panel (not shown). Likewise, a receiving portion of a third wall panel (not shown) may receive protruding portion 112 of second end 108. In this way embodiments of the present invention provide an interior wall system where multiple wall panels may be configured and arranged to substantially connect to each other to form an interior wall having any length, width, height, and shape. [0016] With attention now to Figure 2, an interior wall system 200, having wall panels 202, 204, and 206, is shown. In one embodiment of the invention, wall panels 102, 104, and 106 are made of any type of foam, such as, for example, EPS-cement composites, polystyrene foams such as expanded polystyrene and extruded polystyrene, and polyurethanes. Although wall panels 202, 204, and 206 are shown in Figure 2, it is to be appreciated that any number and configuration of wall panels of

interior wall system 200 is possible and incorporated by embodiments of the present invention. Wall panels 202, 204, and 206 are configured to be arranged to form an interior wall system having any length, width, height, and shape. Moreover, individual wall panels 202, 204, and 206 may have any thickness depending on the design needs of the interior wall structure.

[0017] While wall panels 202, 204, and 206 may have any thickness, each of wall panels 202, 204, and 206 includes a receiving portion and a protruding portion. More particularly, wall panel 202 includes receiving portion 208, located at a first end of the wall panel 202, and a protruding portion 210, located at a second end of the wall panel 202. Wall panels 204 and 206 include similarly situated receiving portions and protruding portions, although only receiving portion 212 of wall panel 206 is shown in Figure 1.

[0018J In addition to wall panels 202, 204, and 206, interior wall system 200 also includes interior wall studs 214, 216, and 218. In one embodiment of the invention interior wall studs 214, 216, and 218 are made of metal, such as, for example, galvanized steel. Each of interior wall studs 214, 216, and 218 is- configured to engage receiving portions and protruding portions of wall panels 202, 204, and 206. For example, interior wall stud 216 is configured to engage protruding portion 210 of wall panel 202 and receiving portion 212 of wall panel 204.

[0019] Finally, interior wall system 200 also includes plate tracks 220 and 222, which attach to the top and/or bottom, respectively, of wall panels 202, 204, and 206. In one embodiment of the invention plate track 220 substantially surrounds the top of wall panels 202, 204, and 206,. while plate track 222 substantially surrounds the bottom of wall panels 202, 204, and 206. Also, in one embodiment of the invention track plates 220 and 222 engage ends of wall studs 214, 216, and 218. Moreover, in one embodiment of the invention, plate tracks 220 and 222 are made of metal, such as, for example, galvanized steel. It is to be appreciated that plate tracks 220 and 222 can be of any length and can vary dimensionally according to design specifications for specific structural implementations.

[0020] In operation, wall panels 202, 204, and 206 are placed in plate track 222, with plate track 222 being attached to a floor or flooring system. Interior wall studs 216 and 218 are placed between wall panels 202, 204, and 206, with protruding end 210 of interior wall panel 202 engaging interior wall stud 216. Interior wall stud 216

also engages receiving end 212 of wall panel 204. Further, interior wall stud 214 engages receiving end 208 of wall panel 202. In addition, plate track 220 is placed on top of wall panels 202, 204, and 206, thus covering wall panels 202, 204, and 206, as well as interior wall studs 214, 216, and 218. Interior wall system 200 is further configured to accept any design finish, such as, for example, plaster, drywall, and other finishes. Interior wall system 200 thus provides a system for building interior walls providing enhanced insulation and an easy and effective method of installation and manufacture.

[0021] In one embodiment of the invention interior wall system 200 may be used in conjunction with other building systems incorporating the use of foam materials into building construction. In this way interior wall system 200 may be part of a building and construction system that uses foam materials along with other components to construct interior and exterior components of buildings. [0022] The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics.. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. AU changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

INDUSTRIAL APPLICABILITY

[0023] Embodiments of the present invention provide systems for constructing interior walls for buildings using foam forms. Although foam forms have been used in constructing exterior walls for buildings, systems for using foam forms for interior walls of buildings have not been developed. Embodiments of the present invention are easily constructed and provide efficient interior walls of buildings with numerous advantages such as excellent insulating qualities for heat and sound, as well as providing a surface onto which finishing materials, such as drywall and plaster, are easily attached.