CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is an International Application, which claims the benefit of U.S. Provisional Application No. 63/172,576, filed April 8, 2021, which is incorporated by reference herein in its entirety for all purposes.

FIELD OF THE INVENTION

[0002] The present disclosure relates to methods of construction, and more particularly in the use of wall systems, ceiling systems, and floor systems in methods of construction.

BACKGROUND OF THE INVENTION

[0003] Current construction methods can be unpredictable. Under current methods a frame of a building is erected, followed by independent teams of plumbers, electricians, etc., who each modify the frame of the building. Each independent modification compounds the chances of human error and increases building costs and time.

[0004] We have invented a method utilizing a new form of construction to optimize speed, efficiency, and cost in construction framing. The disclosed wall system can be created within the confines of a manufacturing facility in order to keep very tight tolerances and decrease mistakes. The wall system ranges from a structurally insulated panel (SIP) to a wall with finished interior and exterior walls with conduit(s) and/or utilities pre-installed within the wall.

SUMMARY OF THE INVENTION

[0005] In one aspect, the present technology features a fabricated wall system containing one or more prefabricated structurally insulated panels. The structurally insulated panels contain an exterior wall, an interior wall, one or more locking devices, and insulation between the exterior wall and the interior wall.

[0006] In some embodiments, the insulation has one or more voids. In preferred embodiments, the one or more voids are partially filled with utility elements, e.g., plumbing, HVAC ducting, electrical conduit, A/V wiring, etc.

[0007] In some embodiments, the utility elements contain plumbing. In other embodiments, the utility elements contain HVAC ducting. In still other embodiments, utility elements contain electrical conduit. In yet other embodiments, the utility elements contain A/V wiring. [0008] In some embodiments, the interior wall comprises one or more voids. In some embodiments, the voids/conduits are shaped, rectangular or cylindrical (e.g., as required and centered at approximately G3" and/or 3 '6" from an edge of the interior wall). The appropriate voids will be placed where desired and/or regionally acceptable to code.

[0009] In some embodiments, the exterior wall and/or interior wall comprise oriented strand board, and or plywood.

[0010] In some embodiments, the insulation comprises extruded graphite polystyrene.

[0011] In some embodiments, the exterior wall contacts siding or roofing.

[0012] In some embodiments, the interior wall contacts dry wall, plaster, concrete, metal sheets or wallpaper.

[0013] In some embodiments, panels are “weathered in” by using a composite serving as flashing applied there between.

[0014] In some embodiments, two or more prefabricated structurally insulated panels (SIPs) are affixed to each other using a locking mechanism.

[0015] In some embodiments, one or more prefabricated structurally insulated panels comprise at least one or more properties chosen from the group of: fire resistant, anti-fungal, insecticidal, non-slip, anti-UV (ultra violet) light, water resistant, or a combination of such properties.

[0016] In some embodiments, one or more prefabricated structurally insulated panels are affixed to siding or roofing using a locking mechanism.

[0017] In another aspect, the present technology features a method of construction using the steps of: a) providing a prefabricated wall system as described in the present embodiments; b) aligning the prefabricated wall system with a building foundation or flooring; and c) locking the prefabricated wall system together and to the foundation or flooring.

[0018] In some embodiments, the method also involves: d) aligning the prefabricated wall system with a prefabricated ceiling or roof; and e) locking the wall system to the ceiling or roof.

[0019] In further embodiments, the method also involves: f) aligning the prefabricated wall system with a prefabricated subfloor or finished floor or roof; and g) locking the wall system to the subfloor or roof or finished floor. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] FIG. 1 illustrates a cross-section of an embodiment of a SIP suitable for the presently disclosed wall system. In this embodiment the SIP comprises 1) a medium density phenolic- impregnated polymer- modified air/vapor barrier on 2) an oriented strand board (OSB) or plywood outer wall, 3) insulation comprising extruded graphite polystyrene (GPS) with embedded conduit for HVAC, plumbing, and electrical utilities, and 4) an inner OSB or plywood wall with 5) finish grade interior (e.g., drywall or plaster).

[0021] FIG. 2 illustrates a cross-section of an embodiment of a SIP suitable for the presently disclosed wall system. In this embodiment the SIP comprises 1) siding on 2) a medium density phenolic-impregnated polymer-modified air/vapor barrier on 3) an OSB or plywood outer wall, 4) insulation comprising extruded graphite polystyrene (GPS) with embedded conduit(s) for HVAC, plumbing, A/V, and electrical utilities, and 5) an inner OSB or plywood wall with 6) finish grade interior (e.g., drywall or plaster or other finishing materials).

[0022] FIG. 3 illustrates a wall system comprising multiple SIPs with multiple layers of cutaway. This embodiment features SIPs with light switches and power outlets embedded in the SIP and finish grade interior, an interior wall to which the finish grade interior is affixed, an exterior wall, insulation between the interior and exterior walls, locking mechanisms (e.g., type A) in the header and side board, and electrical writing.

[0023] FIG. 4 illustrates an embodiment of a wall system comprising multiple SIPs in which the wall system makes up the exterior of the building, and a wall, which is an interior wall, attaches (optionally to a stud) to the wall system making up the exterior of the building. In this embodiment, other described features are also present, including graphite polystyrene (GPS) insulation, an air/vapor barrier, OSB/plywood interior and exterior walls, plaster/drywall interior finish, exterior siding, A/V (e.g., audio, visual, Cat 5 cable), electrical wiring/conduit, HVAC conduit, plumbing conduit, and a footer plate with locking mechanisms.

[0024] FIG. 5 illustrates a wall system comprising multiple SIPs with multiple layers of cutaway. This embodiment features SIPs with studs to form a door frame and a window frame. The embodiment also features insulation between interior and exterior walls, and side boards and a header with locking mechanisms (e.g., types A and B).

[0025] FIG. 6 illustrates a wall system comprising multiple SIPs with multiple layers of cutaway. This embodiment features siding affixed to an air/vapor barrier which is affixed to an exterior wall. The embodiment also features insulation between the exterior wall and an interior wall, and a header, a footer, and side boards with locking mechanisms (types A and B). [0026] FIGS. 7 and 8 illustrate an embodiment of type A and type B locking mechanisms made from an exterior-threaded cylinder, and an interior-threaded receiver.

[0027] FIG. 9 illustrates a cross-section of an embodiment of a SIP of the present technology. This embodiment features siding affixed to building wrap affixed to an exterior wall. The embodiment also features insulation between the exterior wall and an interior wall. The exterior and interior walls also contact a footer and a header with locking mechanisms (types A and B). Finish grade interior is also affixed to the interior wall.

[0028] FIGS. 10 and 11 illustrate embodiments of a wall system utilizing SIPs in which an exterior or interior wall of a SIP has gel or liquid flashing or composite applied (optionally in a channel in the wall) to seal two sections of SIP in a wall system.

[0029] FIG. 12 illustrates a wall system connecting to a flooring and/or ceiling/roof. In this embodiment, the type A locking mechanism is embedded in the face of the wall system, and the type B mechanism is embedded in the edge of the flooring and/or ceiling/roof.

DETAILED DESCRIPTION

[0030] Wall systems represent a method of construction in which some or all of the framing, insulation, utilities, siding, etc. are completed off-site and transported to the construction site.

The wall system can then be attached to the foundation and/or structural support of the unfinished building. Wall systems may comprise structurally insulated panels (SIPs) equipped with a locking mechanism to quickly connect the wall to the unfinished building on-site. SIPs may also be used in constructing a floor and/or roof, which are both including in the term “wall system.” This method of construction allows for fewer modifications and less chance for human error on-site, as well as simple modifications that can be made at the construction site by merely replacing portions of the wall system as desired.

Structurally Insulated Panels (SIPs)

[0031] Structurally insulated panels are pre-fabricated portions of a wall system with an exterior wall, an interior wall, and an optional layer of insulation in between (see, e.g., FIG 1). A SIP may be made of any construction material known in the art suitable for use in a wall. For example, wood products in all various grades such as OSB, Plywood, concrete, and metal, etc. A preferred material is oriented strand board (OSB). SIPs have the advantage of versatility in shape and size, including width, height, and thickness, being suitable to any shape and size used in the art. In preferred embodiments SIPs are between 4 feet and 8 feet in a first dimension (e.g., between 4 and 6 feet, or between 6 and 8 feet), and between 8 and 24 feet in a second dimension (e.g., between 8 and 12 feet, between 12 and 16 feet, between 16 and 20 feet, or between 20 and 24 feet). Finished exterior and interior elements may be affixed to SIPs off-site, including, but not limited to, siding, plaster, drywall, paint, wallpaper, shingles, tile, wood flooring, light fixtures, power outlets, etc. (see, e.g., FIGs. 2 and 3). Insulation used in SIPs may be any used in the art and may be installed and/or modified off-site. In a preferred embodiment the insulation is graphite polystyrene (GPS).

[0032] SIPs may optionally comprise studs as needed for stability or to act as an anchor for a wall extending into the interior of a room (see, e.g., FIG. 4). For example, a SIP may have a stud equipped with locking mechanisms to which another SIP and/or traditionally framed wall may attach. Additionally, SIPs may contain king studs, jack studs, and cripple studs for additional support for windows, skylights, doors, doorways, etc. (see, e.g., FIG. 5).

[0033] SIPs may also contain a footer and/or a header and side boards (see, e.g., FIG. 6). A footer/header and side boards comprise any material compatible with SIPs described herein and act as anchors to add a ceiling/roof to the header, to add the SIP to the flooring/foundation by way of the footer, and/or to adjoin multiple sections of SIP together to form the wall system. Headers/footers and side boards include the necessary locking mechanisms as described herein to join the wall system together, or to affix the wall system to a footer/foundation, and/or to a roof/ceiling.

[0034] Aligned and locked SIPs form the wall system which may be sealed using methods known in the art, including but not limited to a liquid flashing or sealing tape. Adjoining exterior and interior walls may be sealed at the gaps between SIPs, or the entire wall system may be sealed, as in a building wrap (see, e.g., FIG. 7). Alternatively, the interior finish may act to cover the gaps between SIPs, as in wallpaper, drywall, plaster, etc.

Insulations

[0035] Wall systems may use any insulation commonly used in methods of construction, including but not limited to, sheets, foam board, loose-fill, blow-in, and sprayed insulation. The insulation may be installed and modified in a SIP at the point of manufacture or use. The material used in the insulation may be any known in the art, including but not limited to, fiberglass, cellulose, foam, mineral wool, natural fibers, denim, and polystyrenes (e.g., graphite polystyrene). In a preferred embodiment the insulation contains graphite polystyrene. The presently described wall system may be paired with the insulation appropriate for the application. In preferred embodiments, insulation may be rated based on an RSI-value (m ^2- K/W) of between 0.1 and 10, e.g., between 0.1 and 0.2, between 0.2 and 0.3, between 0.3 and 0.4, between 0.4 and 0.5, between, 0.5 and 0.6, between 0.6 and 0.7, between 0.7 and 0.8, between 0.8 and 0.9, between 0.9 and 1.0, between 1.0 and 1.5, between 1.5 and 2.0, between 2.0 and 2.5, between 2.5 and 3.0, between 3.0 and 3.5, between 3.5 and 4.0, between 4.0 and 4.5, between 4.5 and 5.0, between 5.0 and 5.5, between 5.5 and 6.0, between 6.0 and 7.5, between 7.5 and 8.0, between 8.0 and 8.5, between 8.5 and 9.0, between 9.0 and 9.5, or between 9.5 and 10 RSI. An important modification of the insulation is cutting holes or voids into the insulation for heating, ventilating, and air conditioning (HVAC), air barriers, vapor barriers, electrical conduit and wiring, plumbing, etc.

Air and Vapor Barriers

[0036] Air and moisture control are important features of a wall system. Air barriers control the flow of air to prevent heated or cooled air to escape, or to prevent low quality air in to the building. Vapor barriers control the flow of moisture to discourage the growth of mold or fungi in the wall, and to control the humidity inside the building. Because a significant amount of moisture can be in the air, air barriers and vapor barriers may, at times, overlap in function and/or structure. Depending on the conditions under which a wall system is used (e.g., local climate), the design and use of one or more air and/or vapor barriers (e.g., location of the barrier in the wall system, permeability of the barrier, etc.) may change.

[0037] Structurally insulated panels may contain one or more air and/or vapor barriers by, for instance, removing a layer of insulation, leaving a gap between the outer wall and siding (e.g., brick, panel, wood, composite, or vinyl siding), leaving a gap between the inner wall and interior finish (e.g., drywall, treated wall), or by leaving a portion of the gap between the exterior wall and the interior wall of the SIP empty. Air and/or vapor barriers may be sealed using Class I Vapor Retarder (vapor impermeable, 0.1 perm or less), Class II Vapor Retarder (vapor semi- impermeable, between 0.1 and 1.0 perm), or Class III Vapor Retarder (vapor semi-permeable, between 1.0 and 10 perms), or may comprise a gap with weep holes in adjoining layers, as in, e.g., a water resistive barrier (WRB), or a drainage plane.

[0038] A properly sealed SIP may create a vapor barrier with a permeability rating of less than 0.1 perm, or a code-compliant air barrier with a permeability rating between 0.1 and 1.0 perm, e.g., between 0.1 and 0.2, between 0.2 and 0.3, between 0.3 and 0.4, between 0.4 and 0.5, between 0.5 and 0.6, between 0.6 and 0.7, between 0.7 and 0.8, between 0.8 and 0.9, or between 0.9 and 1.0 perm. The wall systems disclosed may use any of the air and/or vapor barrier materials used in the art, including but not limited to, building papers (e.g., asphalt-backed kraft paper, heavy asphalt-impregnated papers, phenolic-impregnated papers, etc.), paints (e.g., vapor- retarding paints, oil-based paints, latex-based paints, etc.), elastomeric membranes and coatings, vinyl wall coverings, extruded polystyrene, plywood, OSB, unfaced expanded polystyrene, and fiber-faced isocyanurate or polyisocyanurate. Other properties of air and/or vapor barriers known in the art may be combined with embodiments of the present disclosure, e.g., density, polymer-modification, and impregnation. A preferred embodiment uses a medium density, phenolic-impregnated, polymer modified air and/or vapor barrier. By installing an air and/or vapor barrier in the SIP, additional air and/or vapor barriers may not be required in the building construction, either in the wall, or elsewhere _^

HVAC

[0039] Heating, ventilation and air conditioning (HVAC) elements and/or systems may be installed in the space between the exterior and interior walls of a wall system in the fabrication stage, or after installation at the construction site. Spaces in the insulation may be left during the installation of the insulation, or may be removed after installing the insulation. The present disclosure is not limiting to the design or materials used in HVAC, and is suitable for any known in the art. For example, split systems, single-unit systems, heat pumps, ductless mini-split systems, packaged heating, and air systems.

Electrical

[0040] Wall systems may be fabricated with electrical conduit and/or wiring. Alternatively, or in addition to wall systems fabricated with electrical conduit and/or wiring, electrical conduit and/or wiring may be installed on-site in or to wall system(s). Any electrical conduit in the art is amenable to the presently disclosed wall system, including but not limited to all internal wall installations covered within the National Electric Code (NEC) and other standard electrical codes or regulations. This includes, romex at all variable sizes, SIMpull, stranded and solid wire of all color variations, cable, A/V wire, data cabling (e.g., Cat 5 cable), security wiring, speaker wire of all gauges, etc. In preferred embodiments, insulation will be removed to install electrical conduit and/or wiring, or the insulation will be installed with spaces for the electrical conduit and/or wiring to be installed. Alternatively, the conduit and/or wiring may be put in place as the insulation is installed around it.

Plumbing

[0041] Wall systems may be fabricated with plumbing, or plumbing may be installed on-site. Any plumbing in the art is amenable to the presently disclosed wall system. This includes but is not limited to all internal wall installations covered within the National Standard Plumbing Code (NSPC) and other standard plumbing codes or regulations. Examples include cast iron, cross- linked polyethylene (PEX, XPE, XLPE), polybutylene (PB), copper, steel, poly vinyl chloride (PVC), etc. In preferred embodiments, insulation will be removed to install plumbing, or the insulation will be installed with spaces for the plumbing to be installed. Alternatively, the plumbing may be put in place as the insulation is installed around it.

Wall Materials

[0042] Wall systems of the present disclosure may have an interior and exterior wall made from the same, or different wall materials. In a preferred embodiment the interior and/or exterior wall contains oriented strand board. Alternatively, the wall systems disclosed herein may use any wall material known in the art (e.g., wood of all grades such as OSB/Plywood, metal such as steel, concrete, stone, brick, etc.). The wall materials may have one or more materials (e.g., layers, coatings) applied with advantageous properties including, but not limited to, fire resistant, anti-fungal, insecticide, and water resistant coatings.

[0043] In a preferred embodiment of the disclosed wall system, the wall material is made of an engineered wood (e.g., plywood, oriented strand board, densified wood, fireboard, particle board, laminated woods, etc.). In a more preferred embodiment the engineered wood is oriented strand board.

Advantageous Materials

[0044] The wall system presently disclosed may have materials (e.g., coatings, layers) with advantageous properties. The materials described herein may have one or more beneficial properties suitable to the use of the wall system. As non-limiting examples, the materials may have fire resistant, anti-fungal, insecticidal, non-slip, anti-UV (ultra violet) light, or water resistant properties, or some combination of such properties. Other coatings known in the art may also be applied to the present embodiments.

Fire Resistant

[0045] Fire resistance may be integrated into the wall systems of the present disclosure. Fire resistance may be through a fire resistant or intumescent materials (e.g., paint, coating, application, etc.). Fire resistant materials include those that act by disrupting the free-radical reactions of fire, those that release water or non-oxygen gases when heated, or those that form a “char” layer of material to protect the flammable materials. Fire resistant materials include, but are not limited to, halogenated fire resistant materials (e.g., tris(2-chloroisopropyl) phosphate), non-halogenated materials (e.g., diethyl hydroxylmethyl phosphonate), non-reactive organic phosphorous (e.g., butyl diphenyl phosphate, dibutyl phenyl phosphate, triphenyl phosphate), reactive organic phosphorous (e.g., diethyl hydroxylmethyl phosphonate), non-halogenated organic phosphorous (e.g., dialkyl hydroxyalkanephosphonate) and inorganic fire resistant materials (e.g., magnesium salts). Such fire resistant materials may be applied before or after the assembly of the SIP or after assembly of the wall. The thickness of the materials, method of application, and other features of the fire resistant materials are commensurate with the best practices of the available art.

Anti-Fungal

[0046] Anti-fungal properties are compatible with the wall systems of the present disclosure. Anti-fungal properties may be achieved through an anti-fungal material (e.g., coating, layer) applied before or after assembly of the wall system. Anti-fungal materials include, but are not limited to, carbamates (e.g., 3-iodo-2-propynyl N-butyl carbamate), 14a-demethylase inhibitors (e.g., propiconazole), and benzimidazoles (e.g., carbendazim). Such anti-fungal materials may be applied before or after the assembly of the SIP or after assembly of the wall. The thickness of the anti-fungal material, method of application, and other features of the anti-fungal materials are commensurate with the best practices of the available art.

Insecticide

[0047] Insecticidal properties are also compatible with the wall systems of the present disclosure. Insecticidal properties may be achieved through an insecticidal material (e.g., coating, layer) applied before or after assembly of the wall system. Examples of such materials include, but are not limited to, pyrethyroids (e.g., permethrin, d-trans-allethrin, resmethrin, tetramethrin, sumithrin), acetylcholinesterase inhibitors (e.g., parathion, diazinon, malathion), cyclodiene-based organochlorines (e.g., heptachlor, aldrin, dieldrin, chlordane, endrin), DEET and DDT. Such insecticidal materials may be applied before or after the assembly of the SIP or after assembly of the wall. The thickness of the insecticidal material, method of application, and other features of the insecticidal materials are commensurate with the best practices of the available art. Water Resistant

[0048] Water resistant properties are also compatible with the wall systems of the present disclosure. Water resistant properties may be achieved through a water resistant material (e.g., coating, layer) applied before or after assembly of the wall system. Examples of such materials include, but are not limited to, polymers (e.g., polyvinyl chloride, polycarbonate, polyethylene, polypropylenes, polyacrylonitrile, polystyrene, acrylonitrile butylene styrene, acrylic polymers) and copolymers. Such water resistant materials may be applied before, during, or after the assembly of the SIP(s) or after assembly of the wall. The thickness of the water resistant material, method of application, and other features of the water resistant materials are commensurate with the best practices of the available art.

Other

[0049] Other advantageous materials (e.g., coatings, layers) include preservatives, non-slip, and UV reflective materials. Non-limiting examples of preservatives include chromated copper arsenate, borates, azoles, triazoles, alkaline copper, alkaline copper quaternary salts, alkaline copper zinc arsenates, tebuconzaole, quaternary ammonium compounds, isothiazolones, and carbamates.

Siding

[0050] The exterior wall of the wall system herein disclosed can be equipped with siding at the point of manufacture or after. Any siding known in the art may be used, including, but not limited to, UV reflective materials, wood siding, shingles, drop siding, stone siding, vinyl siding, PVC siding, metal siding, panels, plastic siding, or any other natural or man-made product intended in the use of siding. In a preferred embodiment, the siding is installed at the point of manufacture to further reduce the on-site construction time.

Interior Utilities

[0051] The interior wall of the wall system herein disclosed may have finished interior utilities (e.g., power outlets, light switches, light bulbs, light strips, speakers, internet or Ethernet cables, monitors, fans, etc.) installed at the point of manufacture or after installing the wall system. Alternatively the wiring and plumbing may be installed during manufacture and certain other of the finished interior utilities installed afterward (e.g., sinks, showers, toilets, bathtubs, etc.). The location of power outlets and light switches is not restricted to any height or the presence of a stud. In preferred embodiments, the power outlets are installed in standard locations (e.g., about 3", or other distances depending on the jurisdiction, from the floor) at the point of manufacture. In another preferred embodiment, the light switches are installed in standard locations (e.g., about 3 '6", or other distances depending on the jurisdiction,) from the floor.

Interior Walls and Finishing

[0052] In some embodiments, the interior wall of the presently disclosed wall system has finishing treatments (e.g., drywall, plaster, wallpaper, paint, tile, wood flooring, or any other man made product intended in the use of interior finishing) installed during manufacture. Alternatively, the interior wall may be finished on-site. Interior walls of adjoining SIPs in the wall system may be sealed with known techniques according to the wall type (e.g., mud and tape for drywall), or by use of a tape (e.g., acrylic tape). The sealing of adjacent interior walls may be accomplished or prepared at the point of fabrication.

[0053] One option for finishing completed walls is to use a tape, for example, on the seams and/or joints of the walls and components, for example, mud and tape, composite tape, or an acrylic tape that is commercial or custom grade.

[0054] Another option would be to use a gel or liquid composite or flashing applied between joints or edges. Gel or liquid flashing (e.g., silyl-terminated polyethers) may be applied standalone, or after a primer (e.g., based on polymethyl methacrylate). To provide additional integration and connection options, some embodiments can include a channel cut to enable application of composite or flashing directly into the channel, in a portion of the channel, or to fill the channel, during manufacture, or on-site, and further enabling transport with the flashing pre-applied ( see e.g., FIG. 10). This would also have the benefit that no mistakes could happen prior to locking the joints together. The channel could facilitate a tighter fit or bond, and/or allow the composite or flashing to expand and flow to fill any air gap therebetween.

[0055] Alternatively, or in addition to the channel embodiment, a gel or liquid composite or flashing could be pre-applied during manufacture or applied on-site, on a cut edge, which “activates” when the other cut edge presses against it and breaks the covering or other mechanism keeping the composite or flashing from causing adhesion or bond ( see e.g., FIGs. 10 and 11). This would be another mechanism for decreasing possible human error, and increasing efficiency and precision in construction.

Locking Mechanisms

[0056] A mechanism is provided for affixing the SIP(s) of the wall system to each other and to the flooring or foundation, or roof of the building. For example, in some embodiments the locking mechanism is a simple turn to lock system. The simple mechanism will be embedded into the wall and join where the wall joins with the flooring or ceiling/roof as seen in FIG. 12. In other embodiments the locking mechanism may utilize a hook or a latch, or a keyed mechanism, or use a specialized hex nut and bolt system, or other customized mechanism to help accommodate and account for the various conduit and properties of the wall system.

[0057] For example, locking mechanisms may come in two types, e.g., a “type A” and a “type B.” A type A locking mechanism might be, for instance, an externally threaded cylinder (e.g., a screw, bolt, etc.) and may be stationary or moveable {see e.g., FIG. 8). A type B mechanism may be, for instance, a hex nut or other internally threaded device whose threads are designed to mate with the threads of a type A locking mechanism. Further, the type A locking mechanism may be embedded on the sides of the wall system, as in FIG. 8, or in the face of the wall system, as in FIG. 12, so that the wall system may be joined to the type B mechanism in the edge of a flooring and/or ceiling/roof. Alternatively, the type A and type B placements may be switched, and/or the placements of the mechanisms on the face/edge may be switched (e.g., the locking mechanism may be on the face of the flooring and/or ceiling/roof, and the locking mechanism may be on the edge of the wall system).

[0058] Locking mechanisms may be embedded in the SIPs along the sides, top, and/or bottom. Locking mechanisms may be embedded in regular or irregular intervals on the SIP. In preferred embodiments the locking mechanisms are spaced between 1 and 16 inches apart, e.g., between 1 and 2 inches apart, between 2 and 3 inches apart, between 3 and 4 inches apart, between 4 and 5 inches apart, between 5 and 6 inches apart, between 6 and 7 inches apart, between 7 and 8 inches apart, between 8 and 9 inches apart, between 9 and 10 inches apart, between 10 and 11 inches apart, between 11 and 12 inches apart, between 12 and 13 inches apart, between 13 and 14 inches apart, between 14 and 15 inches apart, or between 15 and 16 inches apart.

Flooring

[0059] The present wall system technology can also be applied to flooring. The described features can be applied, where appropriate, to the use of the wall system as a floor or subfloor (e.g., insulation, HVAC, plumbing, wiring, etc.). When the wall system is used as flooring or subflooring, further features include interior finish flooring, (including but not limited to, e.g., tile, wood flooring, linoleum, carpet, engineered materials, etc.), natural materials (including but not limited to, e.g., bamboo, cork, concrete, etc.), configurable, movable, and/or heated flooring systems as known in the art, etc. As with other embodiments of the wall system, flooring embodiments can benefit from increased efficiency in construction, decreased construction time on-site, decreased waste, tighter tolerances, and lower cost from being applied and configured with the wall system. Alternatively, a flooring system (e.g., of flooring materials or composition, including materials or flooring known in the art) may be used, and the prefabricated wall systems disclosed herein may be attached to the flooring system described herein or those known in the art. Such flooring systems include flooring, floors, foundations, and subfloors discussed herein and commonly used in the art and/or contemplated in the art.

Ceilings

[0060] The present wall system technology can also be applied to ceilings. The advantageous features described herein can be applied, where appropriate, to the use of the wall system as a ceiling (e.g., insulation, HVAC, plumbing, wiring, etc.). When the wall system is used as a ceiling, further features may include skylights, track lighting, raised levels, molding, etc. As with other embodiments of the wall system, ceiling embodiments can benefit from increased efficiency in construction, decreased construction time on-site, decreased waste, tighter tolerances, and lower cost from being applied and configured with the wall system.

Roofing

[0061] The present wall system technology can also be applied to roofing. The described features can be applied, where appropriate, to the use of the wall system as a roof (e.g., insulation, air/vapor barriers, etc.). When the wall system is used as a roof, further features include exterior finish, e.g., non-slip layer, shingles, tile, shakes, flashing, eaves, gutters, drains, etc. As with other embodiments of the wall system, the roof embodiment can benefit from increased efficiency in construction, decreased construction time on-site, decreased waste, tighter tolerances, and lower cost from being applied and configured with the wall system.

Tolerances

[0062] An important advantage to the wall system presently described is an improvement in the tolerances of construction over an on-site construction method. During construction workers face disadvantages, for example enclosed spaces, hand-held tools, power limitations, poor weather conditions, poor lighting, fatigue, noise, distraction, staffing issues, etc. These often lead to unintended mistakes, physical gaps, or other imprecision in construction. Gaps between sections of framing between interior and exterior sections of wall, between walls and floor, between walls and ceiling, gaps between finished interior (e.g., drywall) and exterior (e.g., siding), misaligned outlets, sockets, pipes, etc., are non-limiting examples of tolerances that the present wall system can improve. Tolerances in construction can be brought down to between 0.05 mm and 2 mm, e.g., between 0.05 mm and 0.1 mm, between 0.1 mm and 0.2 mm, between 0.2 mm and 0.3 mm, between 0.3 mm and 0.4 mm , between 0.4 and 0.5 mm, between 0.5 and 0.6 mm, between 0.6 and 0.7 mm, between 0.7 and 0.8 mm, between 0.8 and 0.9 mm, between 0.9 and 1.0 mm, between 1.0 mm and 1.1 mm, between 1.1 mm and 1.2 mm, between 1.2 mm and 1.3 mm, between 1.3 mm and 1.4 mm, between 1.4 mm and 1.5 mm, between 1.5 mm and 1.6 mm, between 1.6 mm and 1.7 mm, between 1.7 mm and 1.8 mm, between 1.8 mm and 1.9 mm, between 1.9 mm and 2.0 mm, between 0.05 mm and 0.5 mm, between 0.5 mm and 1.0 mm, between 1.0 mm and 1.5 mm, or between 1.5 mm and 2.0 mm.

Efficiency

[0063] Another important advantage to the wall system presently described is an improvement in the efficiency of construction over an on-site construction method. During construction workers face disadvantages, for example enclosed spaces, hand-held tools, power limitations, poor weather conditions, poor lighting, fatigue, noise, distraction, staffing issues, etc. These often lead to unintended mistakes, errors, or other issues necessitating re-doing work in construction. Human errors cause delay and waste in construction project. On-site construction times may be reduced by more than 30% by use of the wall system described herein, e.g., reduced by more than 30% 40%, 50%, 60%, 70%, 80%, 90% or 95%.

[0064] While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations as are within their true spirit and scope.