Abstract:
A pre-fabricated metal stud wall apparatus and system. End studs are placed non-parallel at a 45-degree angle. Abutting adjacent 45-degree walls together, with no loss in square footage can easily create corners. The walls can be made independent of building plan. As such, any 2-foot 8-foot section (or whatever length) can simply be purchased and conformed to any building plan regardless of style or shape (octagonal, hexagonal, square and the like). Each stud includes a series of slots. When the two angled studs are placed side by side, the slots align. A hole present at the end of the wall allows a rod to be placed into it. The rod includes a series of fingers that insert into the aligned slots, thereby locking the adjacent walls together. The walls can include any other number of cutouts for windows, utilities and the like.

Description:
BACKGROUND 
       [0001]    I. Field of the Invention 
         [0002]    The present invention relates generally to the field construction and more particularly to prefabricated wall component apparatus and system. 
         [0003]    II. Description of the Related Art 
         [0004]    Prefabricated steel stud walls are conventionally used to construct various structures and dwellings, such as modular homes, and are typically fabricated with parallel metal studs in pre-selected lengths, such as 2-foot, 4-foot, 6-foot, 8-foot and the like. The resulting component is a planar generally rectangular wall component with squared ends and edges. When the prefabricated walls are placed together to make a structure such as a home, square footage can be easily lost because the walls must be overlapped to create a corner, generally resulting in the loss of one side of the corner by the thickness of the overlapping panel. In addition, lengths of the prefabricated walls often have to be custom made depending on the building plan. 
       SUMMARY 
       [0005]    In general, the invention features a pre-fabricated metal stud wall as a prefabricated wall component apparatus. In the present invention, the end studs are placed non-parallel at a 45-degree angle. In this way, abutting adjacent 45-degree walls together, with no loss in square footage can easily create corners. More importantly, the walls can be made independent of building plan. As such, any 2- foot 8-foot section (or whatever length) can simply be purchased and conformed to any building plan regardless of style or shape (octagonal, hexagonal, square etc.) Furthermore, each stud includes a series of slots. When the two angled studs are placed side by side (for example, when a corner is formed by placing two adjacent walls), the slots align. A hole present at the end of the wall allows a rod to be placed into it. The rod includes a series of fingers that insert into the aligned slots, thereby locking the adjacent walls together. The walls can include any other number of cutouts for windows, utilities and the like. 
         [0006]    In general, in one aspect, the invention features a prefabricated wall apparatus, including an outer wall, an inner wall, vertical studs positioned between the inner and outer walls and connected perpendicular to an top plate and a sill plate and end studs positioned on either ends of the vertical studs and rotated at a 45 degree angle with respective to the inner and outer walls. 
         [0007]    In one implementation, the apparatus further includes a thermal break located between the studs and the outer wall. 
         [0008]    In another implementation, the thermal break forms an airspace between the studs and the outer wall. The airspace can include a two part expanding foam thermal break, which also provides rigidity in the airspace. 
         [0009]    In another implementation, the apparatus further includes a series of slots positioned along the end studs. 
         [0010]    In another implementation, the apparatus further includes an upper opening located on the top plate adjacent the end studs. 
         [0011]    In still another implementation, the connection between the top plate and the end studs has an isosceles trapezoid profile. 
         [0012]    In yet another implementation, the base angles of the isosceles trapezoid profile are 45°. 
         [0013]    In another aspect, the invention features a prefabricated wall system, including a first prefabricated wall panels having an top plate and two end studs, the top plate and end studs forming base angles less than 90 degrees, a second prefabricated wall panel having at least one end stud abutted against and flush with one of the end studs of the first prefabricated wall panel, thereby forming an outer corner and a third prefabricated wall panel having at least one end stud abutted against one of the end studs of the first prefabricated wall panel such that a right angle space is formed between the end studs of the first and third prefabricated panels. 
         [0014]    In one implementation, the system further includes a series of slots along each of the end studs. 
         [0015]    In another implementation, the series of slots on the end stud of the first prefabricated panel that is abutted against and flush with the end stud of the second prefabricated wall panel are aligned with the series of slots on the second prefabricated wall panel. 
         [0016]    In another implementation, the system further includes an top plate on each of the second and third prefabricated wall panels. 
         [0017]    In another implementation, the system further includes an opening on each of the top plates adjacent the series of slots on the end studs. 
         [0018]    In another implementation, the system further includes a rod located within at least one of the openings of the first and second prefabricated panels and positioned parallel the end studs. 
         [0019]    In still another implementation, the system further includes a series of fingers positioned along the rod. 
         [0020]    In yet another implementation, the fingers are positioned within the aligned slots of the end studs of the first and second prefabricated wall panels. 
         [0021]    In another aspect, the invention features a prefabricated wall kit, including a prefabricated wall panel having vertical studs positioned between and perpendicular to an top plate and a sill plate and end studs positioned on either ends of the vertical studs and having base angles of 45 degrees, the end studs having a series of slots along the studs, and an elongated rod having a series of fingers, for insertion in an opening on the top plate so that the fingers fit within the series of slots so that the prefabricated panel can be connected and locked to another prefabricated panel having a corresponding end stud with a series of slots. 
         [0022]    One advantage of the invention is that little to no square footage is lost when the panel apparatuses are connected to one another to create walls and corners. 
         [0023]    Another advantage of the invention is that the prefabricated panels can be preformed into a variety of dimensions. 
         [0024]    Another advantage of the invention is that it enables nominal stock/standard inventory on-hand. 
         [0025]    Another advantage of the invention is that it is adaptable to virtually all house plans. 
         [0026]    Another advantage of the invention is that corners can be secured by locking adjacent panels forming the corners to one another. 
         [0027]    Another advantage of the invention is that panels can be subsequently detached to expand architectural designs. 
         [0028]    Other objects, advantages and capabilities of the invention are apparent from the following description taken in conjunction with the accompanying drawings showing the preferred embodiment of the invention. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0029]      FIG. 1A  illustrates a top view of an embodiment of a prefabricated wall system; 
           [0030]      FIG. 1B  illustrates a side view of an embodiment of a prefabricated wall panel apparatus; 
           [0031]      FIG. 2  illustrates a partial top view of an embodiment of a prefabricated wall panel apparatus; 
           [0032]      FIG. 3  illustrates a side view of an embodiment of a prefabricated wall panel apparatus; 
           [0033]      FIG. 4A  illustrates a partial side view of constituent components of a prefabricated wall system; 
           [0034]      FIG. 4B  illustrates a top view of an embodiment of a connection rod; 
           [0035]      FIG. 5  illustrates a partial close up view of an embodiment of a prefabricated wall system; 
           [0036]      FIG. 6  illustrates an upper partial view of an embodiment of a prefabricated wall system; 
           [0037]      FIG. 7  illustrates a lower partial view of an embodiment of a prefabricated wall system; 
           [0038]      FIG. 8  illustrates a top view of another embodiment of a prefabricated wall system; 
           [0039]      FIG. 9  illustrates a partial top view of another embodiment of a prefabricated wall system; and 
           [0040]      FIG. 10  illustrates two embodiments of connecting plates. 
       
    
    
     DETAILED DESCRIPTION 
       [0041]    Referring to the drawings wherein like reference numerals designate corresponding parts throughout the several figures, reference is made first to  FIG. 1A  that illustrates a top view of an embodiment of a prefabricated wall system  100 . In general, the system  100  includes a number of prefabricated wall panels  105  (prefabricated wall panel apparatuses  105 ). In a typical embodiment, the panels  105  are steel stud panels, although it is understood that other materials such as wood can be used in other embodiments. Typically, the panels  105  include an inner wall  110  and an outer wall  115 . The inner and outer walls  110 ,  115  can be a variety of known materials such as wood, particle board, ply wood, chip/wafer board and the like. In a typical embodiment, additional interior covering is added such as dry wall, and additional exterior covering is added such as vinyl siding or other suitable materials. 
         [0042]    Referring still to  FIG. 1A  and also to  FIG. 1B  that illustrates a side view of an embodiment of a prefabricated wall panel apparatus  105 , it is appreciated that the panels  105  can generally include an upper and sill plate  120 ,  125  as well several studs  130 . The panel  105  can further include end studs  140 . It is appreciated that the studs  130 ,  140  typically include slots  141 . In general, those skilled in the art appreciate that the cutouts are used to decrease weight and increase strength of steel studs. In addition, the cutouts also allow for mechanical chase to be installed as needed for electrical, multi-media and phone lines, as well as for HVAC, Freon and other utilities. 
         [0043]    In a typical implementation, the upper and sill plates  120 ,  125  are arranged parallel to one another. The studs  130  are arranged parallel to one another and in a vertical generally perpendicular position with respect to the upper and lower studs  120 ,  125 . The end studs  140  are also arranged generally orthogonal with respect to the upper and sill plates  120 ,  125 . However, the end studs  140  are arranged in a position that is rotated at an angle such that the ends of the panels  105  form a non-square end. In a typical embodiment, the top profile of each panel  105  is an isosceles trapezoid, the two end studs  140  representing equal non-parallel sides of the trapezoid. Furthermore, the base angles, A, of the top profile are 45 degrees in a typical implementation. It is understood that in other embodiments and implementations, the base angle can be other angles other than 45 degrees. However, it is appreciated that the 45-degree base angle has several advantages that are now discussed in further detail. 
         [0044]    In general, it is desirable for panels such as panels  105  to have pre-fabricated and predictable dimensions, thereby allowing a modular home, for example, to be predictably constructed. As such, the panels  105  can be prefabricated into a variety of dimensions (lengths) such as but not limited to 2-foot, 4-foot and 8-foot sections. It is understood that several standard length sections can be made available depending on the needs of the user. When choosing a predictable section, it is desired to maintain the integrity of dimension, particularly when creating corners in the structure. To preserve length integrity when making corners, two adjoining panels  105  can be butted together as shown in  FIG. 1  in the four corners of the system  100 . By having the ends studs be positioned at 45-degree angles, two end studs of adjacent panels  105  in the corners can be butted together to form a 90-degree corner as desired. The outer walls  115  having the predetermined predictable length can create the corner created without affecting the predictable length. For example, if a corner is to be formed with two 8 foot panels  105 , the resulting corner includes two 8-foot panels  105 , in contrast to the prior art in which a corner would be formed by overlapping two ends of panels at a corner resulting in the loss of length on one side of the corner by the thickness of the overlapping panel. The 45-degree abutting of adjacent panels  105  when creating a corner has further advantages as discussed further in the description below. 
         [0045]    It is appreciated that since the panels  105  desirably prefabricated, the same panels  105  are used to create straight walls of a structure and not just corners of the structure. The same panels  105  can advantageously abutted together side by side to create a straight wall section, as further illustrated in  FIG. 1 . The resulting abutment of the panels  105  side by side to create a straight wall section results in a right angle at the end studs  140  joined side by side. The inner walls  110  of the adjacent panels easily cover the right angle during construction. It is appreciated that the right angle created between the straight walls allows an access space that can advantageously be used to access desirable floor space. For example, if the walls are built on a basement or crawlspace on a wood floor, holes can be cut into the floor for use with utilities such as electrical lines, plumbing gas lines etc and chase for other mechanical installation. Such access is easy and is easily concealed once the inner walls are installed. 
         [0046]      FIG. 3  illustrates a side view of an embodiment of a prefabricated wall apparatus panel  105  illustrating the many features described above and below. 
         [0047]      FIG. 2  illustrates a partial top view of an embodiment of a prefabricated wall apparatus panel  105 . As described above, the panel  105  includes an top plate  120  shown in partial breakaway view to illustrate the top plate  120  connection to the studs  130  in the panel  105 . One of the end studs  140  is shown connected to the top plate  120 . The end stud  140  is connected to the panel at an angle as discussed above such that the end stud  140  is rotated at angles of A and A′ with respect to the inner and outer walls  110 ,  115  as shown. It is appreciated that in a typical implementation A=45° and A′=135°. It is further understood that other angles are possible in other embodiments to create other corner orientations. However, it is appreciated that the 45° angle orientation of the end studs are desirable for to create corners for structures as discussed above. In a typical implementation, the angles A, A′ are supplementary angles. 
         [0048]    Still referring to  FIG. 2 , the panel  105  further includes the inner and outer walls  110 ,  115  as discussed above. It is generally appreciated that the walls  110 ,  115  are used to provide walls for the prefabricated panels  105  onto which other suitable wall material can be mounted. Therefore, it is appreciated that, for example, dry wall can be further connected to the inner wall upon completion of the structure. In addition, for example, suitable external walls can be connected to the outer wall  115 , such as vinyl or brick. In addition, the panel  105  generally includes spacing, d, between the studs  130  and the inner and outer walls  110 ,  115  to provide general thermal insulation as well as a space to add additional insulation. In general, a thermal break  145  can be positioned between the studs  130  and the outer wall  115 . 
         [0049]    Referring again to  FIG. 1A , the system  100  further includes openings  150  cut into the top plates thereby creating access to the butted end studs  140  at the corners. In addition, as mentioned above, a right angle is formed between the end studs  140  for those panels  105  on the straight walls. Both the openings  150  and the right angles provide access to the slots  141  on the end studs. This access provides one of the additional advantages of the end studs  140  being butted together or placed side by side, which is now discussed. 
         [0050]      FIG. 4A  illustrates a partial side view of constituent components of a prefabricated wall system  100 . As described above, the panels  105  can generally include an upper and sill plate  120 ,  125  as well several studs  130 . The panel  105  can further include end studs  140 . It is appreciated that the studs  130 ,  140  typically include slots  141 . In a typical implementation, when two of the corner panels  105  are abutted to one another the slots  141  on each of the end studs align with one another. This alignment creates a conduit through which the end studs  140  of the respective panels  105  can be coupled to one another thereby connecting the respective end studs  140  and therefore the two panels comprising the corner to one another. In this way, the panels  105  can be secured to one another. A connection rod  200  can be inserted into either of the panel openings  150  to accomplish this coupling. 
         [0051]    In general, the connection rod  200  is elongated and runs the entire height of the structure or individual panel  105 . In one embodiment, the rod  200  can include two elongated rectangular panels  205 ,  210  connected to each other at a right angle (or orthogonal).  FIG. 4B  illustrates a top view of an embodiment of a connection rod  200  illustrating the orthogonal arrangement of the rod  200 . The rod  200  can further include a series of fingers  215  that are generally pointed in a downward direction. As such, when the rod  200  is inserted into the openings  150 , the fingers  215  engage with the aligned slots  141  thereby locking the abutted end studs  140  to one another. 
         [0052]      FIG. 5  illustrates a partial close-up top view of an embodiment of a prefabricated wall system  100 . AS discussed above, two panels  105  can be abutted to one another to form a corner. Each panel includes the top plate  120  having an opening  150  into which the rod  200  has been placed allowing the fingers  215  to insert into the aligned slots  141 . Each of the end studs  140  can further include one or more sleeves  170  into which the rod  200  is placed so that the rod  200  can be guided along the inner portions of the end studs  140 . In this way, as the rod  200  is inserted into the openings, the sleeves  170  help prevent the rod  200  from moving in directions other than the desired direction along the end studs, thereby allowing the fingers  215  to be efficiently inserted into the aligned slots  141 . 
         [0053]      FIG. 6  illustrates an upper partial view of an embodiment of a prefabricated wall system  100 . This view illustrates the same orientation of the rod  200  as it is placed into the openings  150  to lock the end studs  140  to one another. Each panel includes the top plate  120  having an opening  150  into which the rod  200  has been placed allowing the fingers  215  to insert into the aligned slots  141 . Each of the end studs  140  can further include one or more sleeves  170  into which the rod  200  is placed so that the rod  200  can be guided along the inner portions of the end studs  140 . It is further appreciated that  FIGS. 5 and 6  illustrate that the rod  200  can be placed into either of the openings  150  to accomplish the coupling or locking together of the end studs  140  and thereby the respective panels  105 . As such, the sleeve on the left side of  FIG. 6  is illustrated as without a rod. 
         [0054]      FIG. 7  illustrates a lower partial view of an embodiment of a prefabricated wall system  100 . This view illustrates that each panel includes the sill plate  125  connected to the end studs  140  as described above. Each of the end studs  140  can further include one or more additional sleeves  170 . As described above, the sleeves  170  help prevent the rod  200  from moving in directions other than the desired direction along the end studs, thereby allowing the fingers  215  to be efficiently inserted into the aligned slots  141 . In addition, the end studs  140  can further include a terminal sleeve  175  that tapers from top to bottom so that the rod  200  can fit into the top of the terminal sleeve  175  but not exit from the bottom of the terminal sleeve  175 . The tapered profile of the terminal sleeve  175  therefore allows the rod  200  to move even closer to the end studs and forced the fingers  215  further into the aligned slots  141 . In this way, the weight of the rod  200  forces the rod  200  into an even more secured position against the end studs  140 . 
         [0055]    In general, the end studs  140  that are abutted to one another in the straight wall portions are generally secured in the structure by being connected to the respective foundations. The rods  200  allow the corner applications of the structures to be secured. In this way, the corners, where structural vulnerability tends to be located are further reinforced by the insertion of the rods  200 . Furthermore, it is appreciated that top caps  180  can be placed over the openings  150  to cover the rods  200 . If it is desired to subsequently expand the structure, the top caps  180  can be removed and the rods  200  can be pulled out of the openings. Panels  105  can subsequently be removed and additional panels  105  added in order to expand on the structure. 
         [0056]    It is appreciated that many architectural designs are possible with the embodiments of the prefabricated wall system  100  and panel apparatuses  105  described herein. For example, the corners of the structure may be formed such that the end studs  140  are not abutted to one another but share a common plane of orientation, P, such as illustrated in  FIG. 8  at  405 . It is further appreciated that a corner  410  can be constructed as needed for those end studs  140  that share the common plane of orientation. 
         [0057]    It is further appreciated that other architectural designs are possible with the embodiments of the standardized prefabricated systems and apparatuses described herein. For example,  FIG. 9  illustrates a partial top view of another embodiment of a prefabricated wall system  500 . The example illustrates that several panels  105  can be used for an architectural profile of a partial hexagon, which can be used for bay windows and the like. In general, the internal angles of a hexagon are 120°. Therefore, the space  505  that remains between the end studs  140  is 30° after subtracting out the 45° of the two end studs. It is understood that the angles described are illustrative only and can differ in actual practice. In addition it is understood that various other designs can further be contemplated using the embodiments of the systems and apparatuses described herein, such as but not limited to octagonal and decagonal profiles and the like. 
         [0058]      FIG. 10  illustrates two embodiments of connecting plates  600 ,  650 . The connecting plate  600  is typically used to cover the corners formed when respective end studs have been connected as described above. The connecting plate  650  is used to cover the straight connections when two of the end studs are placed side by side to create long walls as described above. It is appreciated that other angles can be formed into the connecting plates  600 ,  650 , such as to accommodate the top corner formed, say, between two adjacent walls of the hexagonal example illustrated in  FIG. 9 . It is further appreciated that the connecting plates  600 ,  650  provide additional stability and alignment of the adjacent walls. 
         [0059]    Steel studs have been described in the embodiments herein. However, it is understood that other materials can be advantageously implemented such as but not limited to wood, fiberglass and extruded fiberglass. 
         [0060]    Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, various modifications may be made of the invention without departing from the scope thereof and it is desired, therefore, that only such limitations shall be placed thereon as are imposed by the prior art and which are set forth in the appended claims.