Abstract:
Prefabricated wall segments for construction of buildings. The prefabricated wall segments are lightweight and easy to install and enable an improved ability to install electrical, plumbing, heating and cooling systems as well as insulation in both the vertical and horizontal direction. The prefabricated wall segments can be utilized in new construction as well as in preexisting structures without the need for specialty equipment or tools.

Description:
FIELD 
       [0001]    The field of art to which this invention relates pertains to prefabricated modular shear wall systems with integrated installation channels for electrical, plumbing, heating, ventilation and air conditioning (HVAC). 
       BACKGROUND 
       [0002]    The statements in this background section merely provide background information related to the present disclosure and may not constitute prior art. 
         [0003]    The invention relates to prefabricated modular building construction and units utilized in that construction. Prefabricated building components are used for construction because of their efficiency in installation which can potentially have expense cutting aspects and the reduction in the depletion of natural resources. 
         [0004]    Historically the use of 2×4 studs of wood or other lumber of standard dimensions were most commonly used to fabricate the interior and exterior portions of buildings. Skilled tradesmen and a significant amount of time are needed for the fabrication of buildings by this traditional method of building construction. While prefabricated walls made from studs are available, the weight of the units makes them less efficient for installation. These prefabricated walls do not overcome the issue of the depletion of natural resources because they use standard lumber, the manufacturing of which involves a significant amount of waste material. Due to the weight and size of these types of prefabricated walls there are issues with shipping and storage. The installation of elements such as electrical, plumbing, and heating and cooling elements requires drilling, threading, blocking or other time consuming methods for installation because there are no channels for the horizontal placement of these systems. 
         [0005]    Other systems using prefabricated walls use materials such as metal sheets or poured concrete or cement forms. These types of systems have been unable to overcome the need for skilled tradesmen for installation. Additionally the prefabricated components are heavy and are unable to be installed without the use of specialty equipment such as cranes, lifts, or other heavy mechanical equipment. In addition, many of the systems have been unable to accommodate plumbing, electrical, and HVAC or are make it difficult to install these systems because of the inability to directly install without feeding the systems through complex or small openings. Many of the systems additionally have not been made of materials that help cut costs and reduce the use of non-renewable resources, or are cumbersome and installation is inconvenient and time consuming. 
         [0006]    One such system attempted to overcome some of the issues with standard framing techniques. U.S. Pat. No. 6,584,740 and U.S. Pat. No. 5,440,846. However, the system is made with non-renewable materials, doesn&#39;t accommodate the electrical, plumbing and HVAC systems in an easy to install manner, and are unable to work with existing structures. The system is designed to be a fully assembled system whereby the users have to use all components of the system in order to develop an entire structure. Thus, the system is unable to be integrated into already developed structures. 
         [0007]    Thus, a prefabricated building system made of renewable materials that helps reduce waste, that is easy to install, store and ship is needed. Additionally a prefabricated system that and enables the installation of electrical, plumbing, HVAC, and insulation to be installed vertically and enables easy installation of electrical and plumbing in the horizontal direction without the need for threading, blocking or other time consuming installation issues, has yet to be developed. 
       SUMMARY 
       [0008]    According to various aspects of the present disclosure, there are provided multiple descriptions of the present invention. The present disclosure includes a prefabricated wall segment that is made from materials which are otherwise waste products in the agricultural and forestry industry. The prefabricated building components in the present disclosure are made of natural fast growing plant fibers, such as wood chips or annually re-growing agricultural by-products or waste products like straw, sorghum grass, corn husks, corn stalks, or corn stover, agave, coconut or bamboo fibers or similar suitable natural fibers. The present system also helps in overcoming the need for waste disposal of these byproducts in their respective industries. 
         [0009]    In addition to overcoming the need to utilize the waste associated with the above disclosed industries, utilizing these plant fibers generates a second form of income for farmers and companies in these industries as the byproducts of farming can now be utilized as viable building materials. The use of this abundant waste product allows for the construction of the present invention to be lower in terms of raw materials costs, lower production prices, and higher profit margins for manufactures enabling a delivery of a sustainable product of equal or lower cost than conventional lumber or prefabricated metal structures. These prefabricated structures can be utilized in both new and redesigned structures because of the unique way the prefabricated structures enable all components in modern buildings (electrical, plumbing, and HVAC) to be run through the structures. Additionally, color coded areas which enable the ease of construction and can reduce waste by 10-15% from conventional building methods. 
         [0010]    In one embodiment of the present disclosure the trapezoidal design of the system creates a stronger and more resilient and lighter construction. This enhances the ease of installation but also the overall sturdiness to the structure. As a closed system the wall panel system withstands stronger shear, compression and torsion forces while utilizing less material to achieve these enhanced structural properties. The panels are capable of being cut to length so that they can be utilized to build a particular desired sized structures. Additionally windows, doors and other elements can be cut into the structures for installation of these additional elements in construction. 
         [0011]    The prefabricated wall panels in one embodiment of the present disclosure are equal or similar to standard building materials in size and thus can be installed by two men, eliminating the need for cranes, advanced delivery systems and installation materials, overcoming some of the obstacles of other prefabricated systems. In one embodiment the system can be mixed with conventional framing techniques and used in concert with conventional tools for installation reducing the need for a set of separately skilled laborers for the installation. Many of the other prefabricated systems, using metal or other materials are unable to accommodate horizontal and vertical installation of electrical, plumbing and HVAC systems. In addition, the way the channels are formed eliminates the need to thread these systems through the preformed panels. Thus, enabling the current invention to partner in both new and existing structures, while reducing time and the need for additional blocking, drilling, fishing, and feeding. 
         [0012]    The corrugated core is the main structural element and is generally trapezoidal in design. The corrugated core creates vertical channels running from ceiling to floor in the installed product. The core is a trapezoid design, the vertical channels open alternately toward the interior and exterior of the corrugated core based on the design of the core. In conjunction with outer and inner shear panels these vertical spaces create room for the installation of thermal insulation or the vertical installation of electrical, plumbing and HVAC. A chamber/channel running along each of the sides of the wall panel acts as a location for insertion of connectors and runs vertically between the corrugated core and the external shear panel. This chamber/channel enables multiple prefabricated wall segments to be attached together or for a corner connection to be generated of various angles, 90 degrees being the common angle utilized for standard construction. However, a variety of angles can be developed to accommodate all needs. 
         [0013]    On the interior side of the corrugated trapezoidal core are recessed horizontal channels. These horizontal channels provide space for the installation of standard electrical outlets, light switches and other electrical implements, and the horizontal installation of plumbing. The horizontal channels are positioned at standard heights for bottom wall electrical outlets, mid-height wall outlets and switches for general purpose and kitchen counter height, and another for standard upper wall outlets and j-boxes for wall sconces. An interior shear panel is attached to the inside surface of the trapezoidal core by a mechanical fastener such as glue, nails, screws, rivets, or other similar mechanism used independently or with multiple means. Optionally, drywall can be attached over the shear wall panel as in standard framing and construction. 
         [0014]    Channel connectors can be inserted between two adjoining prefabricated wall segments. The channel connector is complimentary in shape to the chamber/channel that runs vertically along the sides of the prefabricated wall segment. The channel connectors are the male counterpart to the female chamber/channel. The channel connectors can be fabricated from material similar to the prefabricated wall segments or can be made of other materials such as wood, metal, polymers, plastics, composites, or the like. Channel connectors can have a variety of shapes. In one embodiment the channel connector is comb shaped on either side and each side fits into a similarly shaped chamber/channel. The channel connectors can be simply rectangular in shape, have semicircle protrusions or any other structure similar in nature without departing from the scope of the present disclosure. 
         [0015]    A corner can be generated by connecting two units to form an angle at a corner post. Corner posts can be made of standard lumber materials, metal, plastics, or other suitable resources. The corner post is mechanically fastened to each prefabricated wall segment with the additional support of a post cap. The post cap has two legs that are attached to form an angle. Each leg of the post cap has male components similar in shape to the channel connectors and are inserted into the same vertical chambers as the channel connectors. These corner connectors wrap around a standard lumber post which provides structural stability to the connector. In addition to the channel connectors, hold down bolts and hold down brackets are inserted through the corner post and post caps into the prefabricated wall segment from both sides of the corner. 
         [0016]    Thermal insulation can be made from various materials offering superior quality. The insulation will be inserted in the outer insulation channels during production prior to the attachment of the outer shear panel. Additionally, insulation can be installed in channels before or after installation of the wall segments by either cutting insulation to fit or using spray, blown-in, or foam type insulation into the core. Insulation also can be installed on the interior opening vertical chambers prior to attachment of the interior shear panel, again either during production or during installation of the prefabricated wall segments. Insulation can also be installed in the exterior opening vertical chambers either before or during installation. 
         [0017]    An interior channel brace is located internal to the interior shear panel and is screwed or nailed or fixed by some other similar mechanism into the sides of the core channel in the corrugated core. The channel brace is generally shaped the same as the trapezoidal shape to of the corrugated core so as to provide additional integrity to the structure. The channel braces provide additional structural strength where needed, for example for the attachment of a wall connector which runs perpendicular to the main wall segment. It also provides additional mounting surface to which vertical wall rails can be attached by mechanical fasteners such as nails, screws, staples, rivets, glue, or the like, in solo or in combination. 
         [0018]    Top plates and bottom plates are attached to the core and run parallel to each other at the top and bottom of the wall segment, respectively. Bottom plates are attached to the floor through mechanical fasteners. Bottom plates have a base and two parallel protrusions running from the base into the corrugated core and the outer shear panel. The bottom plates provide guides for installation of the prefabricated wall segments and provide attachment to the individual segment. The top plates consist of a body and two vertically oriented rails protruding from the body into the corrugated core, mirroring the bottom plates. The vertical protrusions act as guides as well as attachment points for the core and outer shear panel. Wall rails are of similar design as the bottom and top rails and serve as anchor points for the interior walls which run perpendicular or non-parallel to the exterior walls. The wall rails are mounted to the walls vertically by mechanical fasteners such as glue, nails, rivets, screws, or similar equivalent mechanism as previously described. 
     
    
     
       DRAWINGS 
         [0019]    The drawings herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. 
           [0020]      FIG. 1  depicts an isometric inside view of a segment of a wall panel; 
           [0021]      FIG. 2  is a horizontal section through a corner section; 
           [0022]      FIG. 3  is a vertical cross section of a wall segment assembly; 
           [0023]      FIG. 4  is a horizontal section of a finished assembled wall segment; 
           [0024]      FIG. 5  is a series of multiple versions of the corrugated core. 
           [0025]      FIG. 6  is a two views of the prefabricated wall system and outer shear panel. 
           [0026]      FIG. 7  is an image of multiple panels connected to form interior and exterior walls. 
           [0027]      FIG. 8  is an image of a prefabricated panel connected to standard framing. 
       
    
    
     DETAILED DESCRIPTION 
       [0028]    The following description is merely exemplary in nature and is in no way intended to limit the present disclosure, application or uses. 
         [0029]      FIG. 1  is an exemplary embodiment of an isometric view of the inside of a segment of a wall panel. The cross-section shows the corrugated core  1  which provides vertical channels for installation of insulation, and electrical, plumbing and HVAC systems. Vertical chambers in the corrugated core  1 . 1  are generally intended for plumbing, electrical, HVAC and insulation. Horizontal channels  1 . 2  allow for easy installation of electrical, plumbing and HVAC systems in the interior of the structure without the need for threading as with previously designed systems. An exterior shear panel  2  can be cut to accommodate individual widths of each prefabricated panel system. The exterior shear panel is mechanically fixed to the corrugated core by means of mechanical fasteners such as glues, resins, epoxies, nails, screws, rivets, bolts, staples or similarly suitable fastener. 
         [0030]      FIG. 2  is an exemplary embodiment of two units connected together forming a corner. The image is a horizontal cross section of the two units joined in the corner by corner post  10  and mechanical fastening means  11 . A post cap with legs that extend from either side wraps around the corner post  10  and the leg  9  is a male fitting for the channel/chamber in the exterior shear panel  2 . The exterior shear panel  2  can be cut to length and installed after installation of the corrugated core  1 . Vertical channels  1 . 1  run from ceiling to floor through the corrugated core  1  and enable the installation of electrical, plumbing, HVAC and insulation. Insulation batts  4   a  are optionally added in the prefabricated wall segment either before or during installation. A channel connector  8  connects two adjacent prefabricated wall segments together by insertion of opposing two male ends into adjacent hollow chambers/channels running along either the left or the right side of the segment. 
         [0031]      FIG. 3  is a vertical cross section of a prefabricated wall segment assembled. A top plate  6  is attached at the top of the segment and has two parallel protrusions extending from the body into the corrugated core  1  and the exterior shear panel  2 . The top plate is attached to the corrugated core by mechanical fastening means. The bottom plate  6  mirrors the top plate and is attached to the floor and the corrugated core by mechanical fastening means. The bottom plate  6  consists of a base and two parallel protrusions  7  extending from the base into the corrugated core  1  and the exterior shear panel  2 . The bottom plate  6  acts as a guide for the installation of the wall segment. Four series of horizontal channels  1 . 2 ,  1 . 3 ,  1 . 4 , and  1 . 5  are provided for horizontal installation of electrical components such as (j-boxes and wall sconces), (plumbing and electrical switches and outlets), and (plumbing and electrical switches and outlets at countertop height), and (plumbing and electrical wall outlets), respectively. These horizontal channels enable installation without the need for complex threading, looping, lacing or time consuming measures needs. A channel connector  8  is inserted in the chamber/channel on either side of two adjacent wall segments. The channel connector  8  can have combs on either side or can have any variety of different shapes which are able to be inserted into the chamber/channel. 
         [0032]      FIG. 4  is a horizontal section of a finished assembled prefabricated wall segment. The corrugated core  1  is the main component of the segment. The corrugated core  1  enables attachment of both an interior shear wall panel and an exterior shear wall panel  2  Channel connectors  8  enable connection of two adjacent wall segments and a the male component to the female fitting found in the exterior shear panel  2  located on each side of the wall segment. 
         [0033]    The dashed line  1 . 2   b  in  FIG. 4  shows the depth of the horizontal channels for the installation of electrical and plumbing implements at various heights along the corrugated core  1 . In addition to the horizontal channel vertical channels  1 . 1  show locations for installation of electrical, plumbing, HVAC and insulation (optional)  4   a  during installation of the wall segments. The exterior shear panel  2  and interior shear panel  3  are installed after and can be cut to various dimensions depending on the size of the corrugated core  1 . 
         [0034]      FIG. 4  demonstrates that drywall  4   b  also can be installed against the interior shear panel  3  during installation. Because of the unique design of the prefabricated wall segments the segments can work with existing structures which may are may not have drywall or other commonly used surface treatments such as plaster. 
         [0035]    Channel braces  5  seen in  FIG. 4  can be installed at various locations within the corrugated core  1  and are generally complimentary in shape and size to the trapezoidal structure of the corrugated core. Channel braces  5  add additional strength where needed and are mechanically fixed in place by screws, bolts, nails, glue, epoxy, resins, or similar mechanical means. 
         [0036]      FIG. 5  shows three optional versions for the structure of the corrugated core. V 1  is a corrugated core with an outer shear panel attached to the solid composite corrugated core with a top joint for attaching multiple panels together. V 2  shows another embodiment of the present invention where two corrugated trapezoidal cores are buttressed up together so that the interior portion of the corrugated core creates a honeycomb or hexagonal shape. The interior and exterior shear panels are attached separately. V 3  shows a third embodiment of the trapezoidal corrugated core. In between each of the vertical channels in the exterior portion of the core are channel braces for added support. This particular method could be inverted and the channel braces would be buttressed up against the interior shear panel as an alternative design. The exterior and interior shear panels would be attached separately. 
         [0037]      FIG. 6  depicts an isometric section of the outer shear panel. Shadowed areas  6 . 4  define predetermined areas of the outer shear panel where the panel can be cut to allow for different wall heights. The shadowed areas allow for various cutting heights while still providing enough overlap to enable the male component of the channel connector to insert into the channel connector chamber.  6 . 2  and  6 . 3 , respectively, define the lowest point on a horizontal portion of a wall segment where the panels can be cut and still provide enough overlap for the insertion of the top plate. Portions of the wall can be color coded by adding dye to the plant fibers to enable easier attachment of different elements of the prefabricated construction system.  6   a  is a cross sectional view of the section of the panel in  6   b .  6 . 4  defines an area where the well segment can be cut to at any given area within this portion and still allow for connection of the top plate.  6 . 1  defines the chamber for the insertion of the male component of the channel connector. 
         [0038]      FIG. 7  depicts an interior wall generated by connecting multiple wall segments together  7 . 2  at an angle. Thus plumbing, electrical and all other building components can be run throughout the wall segments and into the interior spaces of the building. Additional support can be provided by connecting an interior channel brace  7 . 1  into the vertical spaces in the wall segment. Bottom plates  7 . 3  are attached to the wall segments and to the subfloor  7 . 4 . 
         [0039]      FIG. 8  depicts a portion of a prefabricated wall segment  8 . 2  connected to standard stud house framing.