Abstract:
A framed forming panel system a plurality of lightweight framed foam panels secured to a plurality of load bearing members having a user defined spacing to form a panel wall; ceiling for floor with a fastening region lattice. Each lightweight framed form panel composed a channel formed in a frame to receive a lightweight panel of foam. Fixation of framed panels to load bearing members in opposition to one another allows the panel walls, ceiling or floor to function as a form to retain an insulative mass placed within the voids created by the opposing framed panels.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
       [0001]    Not Applicable 
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not Applicable 
       THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT 
       [0003]    Not Applicable. 
       REFERENCE TO A SEQUENCE LISTING 
       [0004]    Not Applicable. 
       BACKGROUND OF THE INVENTION 
       [0005]    (1) Field of the Invention 
         [0006]    The present invention relates to a framed forming panel system for use in the construction of permanent or temporary structures, buildings and houses. More specifically the present invention relates to wall, ceiling and floor structures incorporating a top plate, sole plate and a plurality of load bearing members and the methods of constructing the same. 
         [0007]    (2) Background of the Invention 
         [0008]    For over 75 years, permanent and temporary construction of walls, ceilings and floors incorporate a plurality of load bearing members, like studs, ceiling joists or floor joists, spaced between 16 to 24 inches apart and fixed at their ends to either: (i) a top plate and sole plate to form a wall; (ii) top plates to form a ceiling or floor or (iii) sole plates to form a floor. This traditional frame arrangement creates a basic structure upon which strips, panels or sheets of wood, metal or sheetrock are secured to create a wall, ceiling or floor. Windows, doors and other openings can be framed into the walls, ceilings and/or floors prior to placement of strips, panels or sheets of wood, metal or sheetrock across the frame structure. Because the traditional strips, panels or sheets of wood, metal or sheetrock have little insulative properties, insulation for temperature and/or sound must be placed in the voids between the plurality of load bearing members before the strips, panels or sheets are installed. Furthermore, these strips, panels and sheets, once fixed in place, are poor forms to hold or retain insulative materials that are poured into voids between the load bearing-members. The present invention overcomes these shortfalls by attaching rigid framed insulative panels to load bearing members, wherein the framed panels are used as a form for poured-in-place insulation. 
         [0009]    Traditional construction methods for permanent or temporary structures require at least two workers to hang and secure the strips, panels or sheets to the load bearing members due to weight and size of the strip, panel or sheet itself. The present invention is lightweight and rigid and does not require the same number of workers or fasteners. Additionally, the attachment of an article, like a shelf, to the surface of a strip, panel or sheet requires careful alignment over a load bearing structure to ensure a secure attachment to the wall and to prevent tearout of any fasteners. The present invention overcomes this shortfall by incorporating a fastening lattice that is formed across the load bearing members as framed panels are fitted onto the load bearing members. 
       BRIEF SUMMARY OF THE INVENTION 
       [0010]    The present invention is a framed forming panel system  10  including a plurality of lightweight framed foam panels  20  secured to a plurality of load bearing members  30  spaced between approximately 12 to approximately 48 inches apart to form a panel wall  60 , panel ceiling  70  or panel floor  80  with at least one inner region  62 ,  72  or  82 . Each lightweight framed foam panel  20  comprises a channel  222  formed in a frame  22  to receive a lightweight panel of foam  24 . The lightweight foam panel  24  can be fixed into the channel  222  and to the lightweight frame  22  by frame fasteners  28  and/or adhesive  26 . In a preferred embodiment, a plurality of interstitial frames  23  are fixed at user defined spacing inside frame  22  to increase the rigidity of framed panel  20 . 
         [0011]    In a preferred embodiment, the lightweight frame  22  and lightweight foam panel  24  are manufactured prior to the construction of the panel wall  60 , panel ceiling  70  or panel floor  80 . In a preferred embodiment, a lightweight framed foam panel  20  measuring about 1½ inches by about 4 foot by about 8 foot panel is approximately fifty percent (50%) lighter than a  1 / 2  inch by 4 feet by 8 feet oriented strand board (“OSB”) panel used in conventional wall, ceiling or floor construction. This reduction in weight makes it easier for workers to position, hold and secure the panel to load bearing members  30 , like studs  32  or joists  34 . Furthermore, the same lightweight framed foam panel  20  has a significantly greater insulation “R” factor than a similar sized OSB panel. Finally, because framed panels  20  are lightweight, fewer fasteners  90  are required to secure framed panels  20  to studs  32  or joists  34  than use in traditional installations of strips, panels or sheets of plywood or sheetrock. Furthermore, the present invention increases the insulative character of the wall, ceiling or floor over traditional construction methods and components. A further use of the panel system includes use as a form that is left in place to hold a predetermined quantity of mass, wherein the mass can be in the form of a sound proofing mass, thermal mass, ballistic mass or combination thereof of such masses to create a periphery body to protect an interior habitable space against noise, fires, hurricanes, tornadoes, floods and earthquakes depending upon the nature of the mass. In short, the present invention is a lighter panel construction system that is easier to use in the construction of a permanent or temporary wall, ceiling or floor, especially when an insulative mass  100  is poured into a wall, ceiling or floor. Other and further objects, benefits, and advantages of the instant invention have been described above, and further below. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0012]      FIG. 1A  depicts a cross sectional view of a foam panel  24 , adhesive  26 , frame fastener  28 , and a frame  22  that makes up a portion of the framed forming panel system  10 . 
           [0013]      FIG. 1B  is a cross sectional view of a foam panel  24 , adhesive  26 , frame fastener  28 , and a frame  22  with a thicker spine  224  than side walls  226  that makes up a portion of the framed forming panel system  10 . 
           [0014]      FIG. 2  is an isometric view of a framed forming panel system  10  used to construct a wall depicting a plurality of framed panels  20  fixed to a plurality of structural members  30  secured at a user defined spacing  66  between a top plate  50  and a sole plate  40 . Each framed panel  20  in  FIG. 2  depicts interstitial frames  23  fixed at a user defined spacing inside frame  22 . 
           [0015]      FIG. 3  is an isometric view of a framed forming panel system  10  used to construct a portion of a ceiling depicting a plurality of framed panels  20  fixed to a plurality of joists  34  separated from each other by a user defined spacing  66 . 
           [0016]      FIG. 4  is an isometric view of a framed forming panel system  10  used to construct a portion of a floor depicting a plurality of framed panels  20  fixed to a plurality of joists  34  separated from each other by a user defined spacing  86 . Each framed panel  20  in  FIG. 4  depicts interstitial frames  23  fixed at user defined spacing inside frame  22 . 
           [0017]      FIG. 5  is a cross sectional plan view of a framed forming panel system  10  used to construct a wall  05 , ceiling  07  and floor  09  depicting a plurality of framed panels  20 . 
           [0018]      FIG. 6  is a plan view of a wall  05  constructed with a framed forming panel system  10  depicting a fastening region lattice  228 , load bearing members  30  and mass  100 . Each framed panel  20  in  FIG. 6  depicts interstitial frames  23  fixed at user defined spacing inside frame  22 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0019]    Referring to  FIGS. 2 ,  3  and  4 , the present invention is a framed forming panel system  10  including a plurality of load bearing members  30  fixed at a user defined spacing  66 ,  76  or  86  from each other and between either: (i) a top plate  50  and a sole plate  40  to form a wall frame  61 ; (ii) a pair of top plates  50  to form a ceiling frame  71 ; or (iii) a pair of sole plates  40  to form a floor frame  81 . In a preferred embodiment, a plurality of framed panels  20  are fixed to both sides of a wall frame  61  by panel fasteners  90 . See  FIG. 2 . In another embodiment, a plurality of framed panels  20  are fixed to one side of a wall frame  61  by panel fasteners  90 . In another embodiment, a plurality of framed panels  20  are fixed to both sides of a ceiling frame  71  by panel fasteners  90 . See  FIG. 3 . In another embodiment, a plurality of framed panels  20  are fixed to one side of a ceiling frame  71  by panel fasteners  90 . In yet another preferred embodiment, a plurality of framed panels  20  are fixed to both sides of a floor frame  81  by panel fasteners  90 . See  FIG. 4 . In yet another preferred embodiment, a plurality of framed panels  20  are fixed to one side of a floor frame  81  by panel fasteners  90 . In each of the embodiments described above, the user defined spacing between load bearing members  30  can range between about ten inches (10″) to about forty-eight inches (48″). In a preferred embodiment of the framed forming panel system  10 , stud spacing  66  is about sixteen inches (16″) to about forty eight inches (48″) on center for a wall frame  61 . In a preferred embodiment of the framed forming panel system  10 , joist spacing  76  is about ten inches (10″) to about forty-eight inches (48″) on center for a ceiling frame  71 . In yet another preferred embodiment of the framed forming panel system  10 , joist spacing  86  is about ten inches (10″) to about forty-eight inches (48″) on center for a floor frame  71 . 
         [0020]    The cross section form of the load bearing members  30  can be square, rectangular or a generally “U” shape. See  FIGS. 2 ,  3  and  4 . It is contemplated that load bearing members  30  can be fixed to a sole plate  40  or top plate  50  as a single unit or as two units fixed to one another to form a load bearing member  30  with an I-beam or box-beam cross section to create a larger fastening surface to which a framed panel  20  can be affixed. See  FIGS. 2 ,  3  and  4 . The width of a load bearing member  30  ranges from about one and one-quarter inches (1¼) to about three inches (3″) to provide a fastening surface  36  of about 1¼ inches across the width of a load bearing member  30 . Load bearing member  30  can be constructed of wood, steel, carbon fiber or a combination thereof. In a preferred embodiment, load bearing members  30  are wooden, galvanized steel or a combination of both. 
         [0021]    A framed panel  20  of the framed forming panel system  10  includes a foam panel  24  fixed by frame fasteners  28  and/or adhesive  26  into a generally “U” shaped channel  222  formed in a frame  22  that surrounds the periphery of the foam panel  24 . See  FIGS. 1 through 6 . Frame fasteners  28  can be screws, self tapping screws, rivets, arrow clips, canoe clip, Christmas tree clips, and/or key hole clips. In a preferred embodiment, frame fasteners  28  are self tapping screws. Adhesive  26  can be drying adhesives, pressure sensitive adhesives, contact adhesives, hot adhesives, multi-part reactive adhesives, one part reactive adhesives, natural adhesives, synthetic adhesives of a combination thereof. In a preferred embodiment, adhesive  26  is a two-part reactive elastomeric polyurethane froth adhesive. 
         [0022]    A framed panel  20 , as disclosed herein, has a significantly greater rigidity over that of an unframed foam panel  24  or even a traditional sized sheet of ¼ or ½″ plywood. With the inclusion of interstitial frames  23  within frame  22  an enhanced embodiment of a framed panel  20  is able to provide even greater rigidity over an unframed foam panel  24  or traditional sized sheet of plywood. Without a frame  22  supporting its periphery, a foam panel  24  is susceptible to bending, flexing and breaking. An unframed foam panel  24  or even a traditional sized sheet of ¼″ or ½″ plywood are not suitable for use as a form to support and contain a poured in insulative mass  100  because of its lack of rigidity and firmness as a construction material. By fixing a frame  22  to a periphery of a foam panel  24 , a framed panel  20  is formed that protects against the tear out of panel fasteners  90  as well as protects against compression of foam panel  24  at its periphery. In short, a framed panel  20  of the present invention allows a foam panel  24  to be securely mounted to a plurality of load bearing members  30  to be used not only as insulation but as a durable wall covering or as a form to contain and hold an insulative mass  100 . Furthermore, when a plurality of framed panels  20  are installed across a plurality of load bearing members  30 , the frames  22  further provide a fastening region lattice  228  between load bearing members  30 . See  FIGS. 2 ,  3 ,  4  and  6 . Such a fastening region lattice  228  provides additional locations to fasten or securely fix articles (such as shelves) to a wall  05 , ceiling  07  or floor  09  between load bearing members  30 . In a preferred embodiment, a plurality of interstitial frames  23  set at user defined spacing inside the frame  22  not only increase rigidity of the framed panel  20 , but also increase the area of a fastening region lattice  228 . Compare  FIG. 3  with  FIG. 4 . 
         [0023]    The rigidity of a framed panel  20  is determined largely by the gauge of frame  22 , depth of channel  222  and thickness of foam panel  24 . A lighter gauge frame  22  will not be as rigid as a heavier gauge frame  22 . It is contemplated that the gauge of a frame  22  can range between approximately twenty six (26) gauge to approximately twelve (12) gauge. In a preferred embodiment, frame  22  has a uniform gauge. See  FIG. 1A . In another embodiment, frame  22  has a spine  224  with a gauge that is different than the opposing channel walls  226 . In a preferred embodiment, spine  224  has a gauge that is thicker than the opposing channel walls. See  FIG. 1B . The depth of a frame channel  222  can also affect the rigidity of a foam panel  24 . The rigidity of framed panel  20  with a deep channel  222  is greater than a framed panel  20  with a shallow channel  222 . It is contemplated that a frame  22  can be constructed from metal, plastic, carbon fiber or a combination thereof. In a preferred embodiment, channel  222  is a generally “U” shaped channel  222  of approximately one inch (1″) depth and approximately one and one half inch (1½″) width formed in an approximately sixteen (16) to approximately twenty (20) gauge galvanized metal frame  22 . In another preferred embodiment, channel  222  is a generally “U” shaped channel  222  of approximately one inch (1″) depth and approximately one and one half inch (1½″) width formed in an approximately sixteen (16) to twenty (20) gauge plastic frame  22 . 
         [0024]    It is contemplated that foam panel  24  is constructed from rigid cellular polystyrene. In a preferred embodiment, foam panel  24  is constructed from rigid cellular polystyrene thermal insulation that meets or exceeds ASTM C578 standards. In a preferred embodiment, a single sheet of foam panel  24  fits within a channel  222  formed in frame  22 . In another embodiment, more than one sheet of foam panel  24  is installed within channel  222  formed in frame  22 . It is contemplated that a covering  242 , such as a metal foil, a plastic sheet, and/or a paper sheet may be affixed to at least one surface of foam panel  24  for enhanced thermal insulation, panel stability and/or panel durability. 
         [0025]    In a preferred embodiment, a plurality of load bearing members  30  are studs  32  aligned to form a generally vertical planar wall frame  61  with an inner wall region  62  and an outer wall region  64 . See  FIG. 2 . A series of framed panels  20  are butted up against one another and affixed to a plurality of studs  32  by panel fasteners  90  to form a panel wall  60  with a fastening region lattice  228 . In another preferred embodiment, framed panels  20  are affixed to both sides of a plurality of load bearing members  30  to form voids  68  in panel wall  60 . See  FIG. 2 . It is contemplated that the length, width and thickness of a framed panel  20  would be similar to the dimensions of conventional plywood panels or sheetrock panels used to cover a plurality of studs  32  with a user defined stud spacing  66 . In a preferred embodiment, framed panel  20  is about four feet (4′) wide, about eight feet (8′) long and about one and one half inches (1½″) thick. In another preferred embodiment, framed panel  20  is about two feet (2′) wide, about eight feet (8′) long and about two inches (2″) thick. In either preferred embodiment described above, framed panels  20  are stacked on top of each other to cover an eight foot (8′) tall wall. 
         [0026]    In a preferred embodiment, a plurality of load bearing members  30  are joists  34  aligned to form a generally horizontal planar ceiling frame  71  with an inner ceiling region  72  and an outer ceiling region  74 . See  FIG. 3 . A series of framed panels  20  are butted up against one another and affixed to the plurality of joists  34  by panel fasteners  90  to form a panel ceiling  70  and a fastening region lattice  228 . In another preferred embodiment, framed panels  20  are affixed to both sides of a plurality of load bearing members  30  to form voids  78  in panel ceiling  70 . See  FIG. 3 . It is contemplated that the length, width and thickness of a framed panel  20  would be similar to the dimensions of conventional panels used to cover a plurality of joists  34  with a user defined joist spacing  76 . In a preferred embodiment, framed panel  20  is about two feet (2′) wide, about eight feet (8′) long and ranges between about one and one half inches (1½″) to about two and one half inches (2¼″) inches thick. 
         [0027]    In a preferred embodiment, a plurality of load bearing members  30  are joists  34  aligned to form a generally horizontal planar floor frame  81  with an inner floor region  82  and an outer floor region  84 . See  FIG. 4 . A series of framed panels  20  are butted up against one another and affixed to the plurality of joists  32  by panel fasteners  90  to form a panel floor  80  and a fastening region lattice  228 . In another preferred embodiment, framed panels  20  are affixed to both sides of a plurality of load bearing members  30  to form voids  88  in panel floor  80 . See  FIG. 4 . It is contemplated that the length, width and thickness of a framed panel  20  would be similar to the dimensions of conventional panels used to cover a plurality of studs  32  with a user defined joist spacing  86 . In a preferred embodiment, framed panel  20  is about two feet (2′) wide, about eight feet (8′) long and ranges between about one and one half inches (1½″) to about two and one half inches (2½″) thick. 
         [0028]    An insulative mass  100  of the framed forming panel system  10  can be acoustic, thermal and/or ballistic. A user&#39;s selection of an insulative mass  100  is, in part, determined by the depth of load bearing members  30  as well as the type of insulation required, sound, thermal, ballistic or a combination thereof. Insulative mass  100  is placed in voids  68 ,  78  and  88  between opposing framed panels  20 . See  FIG. 6 . It is contemplated that insulative mass  100  can be air, paper fiberglass, mineral wool, rock wool, slag wool, plastic, natural fibers, polystyrene foam, polyisocyanurate foam, polyurethane foam, open cell foam, closed cell foam, rubber, sponged melamine, vermiculite, perlite, dirt, asphalt, concrete, cement and/or any combination thereof. It is further contemplated that such insulative mass  100  can be in the form of blankets, rolls, pellets, boards, blocks, liquids that solidify after being poured-in-place or a combination thereof to be placed in voids  68 ,  78  or  88 . 
         [0029]    It is further contemplated that a framed forming panel system  10  as described herein could be used in conjunction with traditionally constructed structures to reduce construction costs or make repairs to existing traditionally constructed structures after fire, flooding or other damage. It is further contemplated that a framed forming panel system  10  as described herein can be used to construct temporary housing  100  with at least a panel floor  80 , a panel ceiling  70  or a combination of both. See  FIG. 5 . Outer wall regions  64  would be covered with a flexible material  102  temporarily fastened to a plurality of studs  32  by refastenable fasteners  92  like ties, hook and loop, buttons, snaps or a combination thereof. 
         [0030]    In a preferred embodiment, an insulative mass  100  is formed about the periphery of a habitable space  03  by using a framed forming panel system  10  wherein the walls  05  of a habitable space  03  are constructed from a plurality of load bearing members  30 , namely studs  32 , fixed between a sole plate  40  and a top plate  50  at a user defined stud spacing  66  to form a wall frame  61  with an inner wall region  62  and an outer wall region  64 . A plurality of framed panels  20  are fastened to said plurality of studs  32  to cover said inner and outer wall regions  62  and  64  to form a plurality of voids  68  in said wall frame  61 . A user defined amount of insulative mass  100  is placed in said plurality of voids  68  and held in place by the plurality of framed panels  24  attached to the plurality of studs  32  to insulate, along the periphery, the habitable space  03 . 
         [0031]    In another embodiment, an insulative mass  100  is formed about the ceiling  07  of a habitable space  03  by using a framed forming panel system  10  wherein the ceiling  07  of a habitable space  03  is constructed from a plurality of load bearing members  30 , namely joists  34 , fixed between 2 pairs of opposing top plates  50  at a user defined joist spacing  76  to form a ceiling frame  71  with an inner ceiling region  72  and an outer ceiling region  74 . A plurality of framed panels  20  are fastened to said plurality of joists  34  to cover said inner and outer ceiling regions  72  and  74  to form a plurality of voids  78  in said ceiling frame  71 . A user defined amount of insulative mass  100  is placed in said plurality of voids  78  and held in place by the plurality of framed panels  24  attached to the plurality of joists  34  to insulate the ceiling  07  of habitable space  03 . 
         [0032]    In another embodiment, an insulative mass  100  is formed about the floor  09  of a habitable space  03  by using a framed forming panel system  10  wherein the floor  09  of a habitable space  03  is constructed from a plurality of load bearing members  30 , namely joists  34 , fixed between 2 pairs of opposing sole plates  40  at a user defined joist spacing  86  to form a floor frame  81  with an inner floor region  82  and an outer floor region  84 . A plurality of framed panels  20  are fastened to said plurality of joists  34  to cover said inner and outer floor regions  82  and  84  to form a plurality of voids  88  in said floor frame  81 . A user defined amount of insulative mass  100  is placed in said plurality of voids  88  and held in place by the plurality of framed panels  24  attached to the plurality of joists  34  to insulate the floor  09  of habitable space  03 . 
         [0033]    Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the claims set forth below.