Abstract:
A wall panel supporting unit and system of constructing a wall utilizing a series of the wall panel supporting units in place of a traditional stud wall. The individual wall panel supporting units are of unitary construction and are generally rectangular. The units are corrugated and the resulting ridges function in the same manner as individual studs in a traditional wall, by creating a space within the wall for insulation, electrical wiring and similar uses. The individual units are fastened together, and attached to parallel tracks along the ceiling and floor to ensure a straight wall when panel sheathing such as drywall is applied. The individual units generally conform to each other when stacked together and offer a significant reduction in required shipping space.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to wall construction and units utilized in that construction and, more specifically, to prefabricated wall panel support units for construction of a rough wall, or of a wall structure to support wall panels in the interior of a building. The present invention relates, specifically, to the construction of walls, interior to a structure having a defined ceiling or overhead, and a defined floor. 
     The concept of building an interior wall by utilization of a frame, upon which to attach wall panels, including drywall, or like materials, is a method historically long known. Traditionally, such walls are constructed of wood, perhaps most commonly 2×4 “studs” which are fabricated on site, with upright studs located at desired uniform intervals, for the attachment of drywall or other wall panel type material. Even predating the days of drywall, lath construction across the exterior of the studs, in the wall assembly, was utilized to provide a base for a plaster wall. 
     Traditional wall stud construction poses a number of problems, some particular to the novice, and some, to novice or skilled tradesman alike. First, utilization of individual units of 2×4 or other uniform sized lumber requires fabrication on site and a significant degree of skill, often putting this technique beyond the capabilities of anyone but the professional tradesman. While prefabricated stud wall units are known, these are cumbersome and heavy, and present difficulties in transportation and storage. Another obstacle to overcome in traditional stud wall assembly is the inherent variation in the material itself. Even high grade lumber presents some variation from piece to piece and is subject to warping when exposed to the elements, or variation in humidity and/or temperature exposure. Further, utilization of the very highest grade lumber for construction of wall panel support walls (stud walls) would be prohibitively expensive. It is difficult, therefore, with traditional construction methods, to create a wall panel support wall which is linearly straight, and uniform, from its base at the floor, to the ceiling. The same considerations that apply to the straightness of the walls, and the linear smoothness from floor to ceiling also apply, obviously, to thickness of walls, which are not always uniform utilizing traditional stud wall construction methods. 
     Utilization of prefabricated stud walls likewise does not address or solve all of the previous problems. As previously stated prefabricated stud walls, of traditional materials, present significant obstacles in shipping and storage, and, further, are dependent upon the composition of the base material which, usually, is wood. The variation in the base materials, in stud walls, has been addressed somewhat, in utilization of metal studs, as well. However, on-site construction using metal studs places utilization even further out of the reach of anyone but the skilled tradesman, and prefabricated metal stud walls present like difficulties in transportation and storage. Further, utilization of prefabricated individual panels does not eliminate the subjectivity of placement and alignment and, therefore, does not ensure that a combination of panels, when installed, will be linearly, or vertically, true. 
     Numerous examples which attempt to address portions of this problem exist in the prior art. U.S. Pat. No. 5,581,969, issued to Kelleher, for a prefabricated building element, discloses a modular building panel member having one or more V-shaped reinforcing stud members; U.S. Pat. No. 2,576,530, issued to Medal, discloses a construction panel composed of a pair of plywood sheets or other like materials glued or otherwise affixed about a thin corrugated sheet. U.S. Pat. No. 5,067,296, to Brown et al, discloses a modular insulated wall panel system utilizing preconstructed wall panel elements. The use of corrugated steel sheets in floor construction, for receiving a concrete, cement, or plaster slurry, is also disclosed by U.S. Pat. No. 3,802,147, to O&#39;Konski. 
     While all of the referenced prior art discloses attempts which, in some respect, address one or more problems related to traditional stud wall or wall panel support, none of the prior art provides, or teaches, a wall component, or system of wall construction, which adequately addresses the combined concerns of on-site assembly which is both horizontally and vertically true, ease in storage and maintenance, both from a weight and volume standpoint, and which is susceptible to utilization by persons other than skilled tradesman. 
     Accordingly, a need exists for a prefabricated construction unit, capable of supporting a sheet of wall panel material, such as drywall, fabricated wood paneling or like materials, which panel units are of unitary, manufactured construction, to ensure uniformity within required tolerances and which, when installed in combination, will provide a true wall support unit, both vertically and horizontally. 
     Further, a need exists, for a wall construction system utilizing uniform panels, which is susceptible of uniform and correct installation by persons with less than optimal trade experience and which provides a means for easily joining uniform support units or panels 
     A further need exists to supply a prefabricated wall panel support unit for utilization in such wall construction system which, without sacrificing required support strength, is optimally lightweight and conformed to be stackable, for ease and efficiency in shipment and storage, both on and off the construction site. 
     As noted, the existing prior art does not satisfy these requirements. 
     SUMMARY OF THE INVENTION 
     The present invention has been designed to overcome shortcomings in the prior art and to address the needs as noted above. The present invention is directed to the provision of a prefabricated unit, to be utilized in series, in wall construction, to support finished wall panels, and, a system of wall construction utilizing such panels, to allow a person of ordinary skill to assembly, on site, an interior support wall between an existing floor and ceiling, which wall is uniformly true, both vertically and horizontally, and in width. 
     More specifically, the present invention is directed to a system of wall construction, and a primary unit within that system which is of unitary manufactured construction, and which may be extruded, from various materials, to provide uniform construction parameters in width, height and length, as well as optimizing, by selection of the appropriate materials, and design of the unit itself, the strength to weight ratio of the unit and to allow a prefabricated wall unit which may be conformably stacked, for optimum efficiency in shipping and storage, both on and off site. 
     According to an important feature of the invention, there is provided a support unit which, within the system of wall construction, may be joined in series, and to which a wall sheathing of panels of different composition, including drywall or wood paneling, may be attached. This support unit is constructed of an extruded material which may be metal, composite, or synthetic material, which forms a rigid sheet. In general, the outward dimensions of the sheet are rectangular, although the sheet, itself, along its vertical surface, is uniformly corrugated to provide a series of ridges on one side and corresponding furrows on the other. The ridges are uniformly spaced and have at least a partially flat extended outer surface, to which the wall sheathing may be attached. In general, the vertical ridges of the corrugated construction are parallel, and may be spaced as desired, in traditional on center spacings, as normally utilized in construction. In practice, the panels may be of traditional 4×8 foot construction, but may, as desired, be of any particular dimension. As is evident from the stated corrugated construction, on the opposite side of each panel, for each corrugated ridge, there is a corresponding corrugated furrow. The corrugated construction is such that, when a combination of support panels are stacked, the corrugated ridges of each panel conformably fit, when so stacked, within the corrugated furrows of the preceding panel, to maximize space efficiency in shipping, handling and storage. As stated, the construction of the support units is substantially rectangular, and the vertical furrows and ridges are parallel to the vertical sides of the panel. The upper edges and lower edges of the panel are essentially parallel to each other, and the profile of the panel, from the front, is generally rectangular. 
     According to an important feature of the invention, each support panel is conformed so that it is uniformly mateable with another like support panel, in order to form a continuous support wall. This is accomplished by recessing an adjacent area of the panel along one vertical edge, parallel to the corrugated ridges. The adjacent panel area is recessed, in its entirety, so that one side of the panel area is recessed and the opposite side of the panel area extended a distance equal to the thickness of the panel, which is substantially uniform thereout, including through the corrugated portion. Accordingly, the other vertical edge of a like panel, parallel to the corrugated ridges, may then be placed over the recessed area of the initial panel so that the top edges of the panels so mated are linearly aligned to form a straight line, with the exception of the corrugated ridges and furrows and which, when so aligned, provide a uniform supporting surface between both panels, susceptible of mounting a continuous straight sheath of drywall or other wall panel material. Each of the corrugated ridges additionally has a flat exterior linear surface running between the top edge and bottom edge of the panel unit to facilitate attachment of the wall sheathing material. This flat surface on each of the corrugated ridges is parallel to the rectangular profile of the support unit. 
     According to a further important feature of the invention, in order to ensure uniformity in construction, each support unit or panel has a series of uniform, pre-drilled holes, each running vertically between the upper and lower surfaces adjacent to and parallel to each vertical edge. These holes, at one edge, will be through the recessed vertical area, and each pre-drilled hole along the recessed area will correspond in vertical distance from the top and bottom of the panel with a pre-drilled hole along the other edge so that, when the non-recessed edge of a support panel is mated with the recessed edge of another like support panel, so that the top edge and lower edge are in common, the pre-drilled holes of each panel will be aligned with each other to allow the panels to be fixed together by a bolt, screw, or other fastening means inserted through one or more of the pairs of aligned pre-drilled holes. 
     According to a further important feature of the invention, in order to facilitate the stated conformity of like panels for stacking purposes, the corrugated ridges on each panel are progressively narrower in extension from the surface of the panel to the exterior flat surface of the ridge, while maintaining the uniform thickness of the panel through the corrugated areas. 
     According to a further important feature of the invention, the wall assembly system portion of the invention includes a series of the stated support panels, joined as stated, and further includes a pair of corresponding tracks, one track affixed to the ceiling or overhead of the area in which the wall is being constructed, and the other corresponding track being affixed to the floor surface of the area in which the wall is being constructed. These two tracks are aligned in vertical parallel to ensure linear straightness in the constructed wall. Typically, these supports may be formed of elongated members having two elongated flat sides joined at a common edge in what is typically understood as an L-shaped or “angle iron” configuration. As to the ceiling track, one flat side of the track is attached to the ceiling or overhead so that the other second flat portion of the track extends a distance vertically downward and linearly along the length of the track. Likewise, for the floor track, one flat surface is affixed to the floor surface with the other flat surface extending upward, and linearly along the track. Each support unit is then attached along its upper edge, sequentially, to the downward extending portion of the upper track and each support unit, sequentially, is attached along its lower edge to the upward protruding portion of the lower track. 
     According to a further feature of the invention, each support unit may include pre-drilled holes parallel to and along its upper edge, in areas of the support unit which are not corrugated, and likewise may have pre-drilled holes parallel to and adjacent to its lower edge, in areas which are not corrugated. Likewise, the downward extending portion of the upper track and the upward extending portion of the lower track may have pre-drilled holes at designated intervals so that, when each panel of the unit is sequentially placed against the upper and lower tracks, one or more of the pre-drilled holes along the support unit&#39;s upper edge will correspond with one or more pre-drilled holes in the upper track and, likewise, one or more pre-drilled holes along the lower edge of the support unit will correspond with one or more of the pre-drilled holes in the lower track, so that a bolt, screw, or other fastening means may be inserted through the corresponding, or aligned, holes to secure each support unit, sequentially, to the upper and lower tracks. 
     According to a further feature of the invention, each of the support units has a series of openings extending along each side of the corrugated ridges and corresponding furrows, between the upper edge of the support unit and the lower edge of the support unit. These openings may be utilized for the passage of electrical conduit, attachment of wall panel fasteners, telephone, computer or other utility installation, or the like. Ideally, these openings are arranged so that they correspond and are horizontally aligned, on each side of the ridge. 
     As stated, the individual support units may be constructed of any suitable material and may be of metal, composite construction, plastic polymer, or other synthetic material. 
     The above and additional features of the invention may be considered and will become apparent in conjunction with the drawings in particular, and the detailed description which follows. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The following detailed description is best understood by reference to the following drawings, in which: 
     FIG. 1 is a perspective view of a partially completed wall assembly in the preferred embodiment; 
     FIG. 2 is a top cross-sectional view taken on line  2 — 2  of FIG. 1; 
     FIG. 3 is a fragmented front view of an individual wall panel support unit having three corrugated ridges; 
     FIG. 4 is a top view of an individual wall panel support unit and corresponding furrows having three corrugated ridges and showing the uniform thickness of the unit; 
     FIG. 5 is a fragmented front view of an individual wall panel support unit having a pair of corrugated ridges; 
     FIG. 6 is a top view of an outline of an individual wall panel support unit having a pair of corrugated ridges and corresponding furrows; 
     FIG. 7 is an exploded side view of three units in a stacked configuration; and 
     FIG. 8 is a perspective side view of a combination of individual units stacked within a shipping container. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The invention wall support unit and wall system, broadly considered, includes a wall system assembly  10 , which in turn includes as major components, a plurality of wall panel support units  20 , a first or upper track member  30  and a second or lower track member  40 . 
     The wall system assembly  10  is configured for installation between an existing ceiling or overhead  11  and a floor or base assembly  12 . 
     The wall panel support unit  20  is comprised of rigid material and in practice may be constructed of extruded metal, including, but not limited to, aluminum, composition material, including, but not limited to, a particle board composite, plastic polymer, fiberglass or other material which may be formed or extended to form a rigid member. 
     Unit  20  may be generally described as a rigid sheet member with a first outwardly or exterior broad surface  21  and an oppositely outwardly or exterior broad surface  22 . Broad surfaces  21  and  22  define a substantially uniform thickness A throughout unit  20 . 
     Unit  20  has an upper edge  23  and a lower edge  24 , a first linear side edge  25  and a second linear side edge  26 . Upper edge  23  and lower edge  24  are substantially in parallel, and side edge  25  and side edge  26  are substantially in parallel. When viewed from a side perspective, the outline or profile formed by the boundary of upper edge  23 , lower edge  24 , first side edge  25  and second side edge  26  is generally rectangular. Although unit  20  may be fabricated in any rectangular configuration, in the preferred embodiment side edges  25  and  26  will be significant greater in length than upper edge  23  and lower edge  24 . Unit  20  is further of corrugated construction and in that regard, first exterior broad surface  21  additionally defines a plurality or series of uniform ridges  27 . Each uniform ridge  27  extends between upper edge  23  and lower edge  24  on broad surface  21 , generally in parallel with side edges  25  and  26 . In the preferred embodiment, each uniform ridge  27  is spaced at an equal interval B from any adjoining ridge  27 . These intervals B would normally be at standard building specifications. The uniform ridges function in the same manner as traditional vertical studs to secure drywall, wood panels or other wall sheathing material. 
     Corresponding to the uniform ridges  27  on surface  21 , surface  22  defines an equal series or plurality of uniform furrows  28 . Each furrow  28  is aligned correspondingly with a ridge  27  between the upper edge  23  and lower edge  24  and is likewise substantially vertically parallel with edges  26  and  27 . As may seem apparent from the views of FIGS. 7 and 8 and the cross-sectional view of FIG. 2, the corresponding alignment of each furrow  28  with a ridge  27  maintains the uniform thickness A. Each uniform ridge has a width C at where it conmmences extension from the broad surface  21  and further has a generally planar linear surface  29 , which surface  29  is generally parallel to rectangular outline or profit of unit  20  at the point of furthest extension of ridge  27  from broad surface  21 . Surface  29  has a width D and ridge  27  is progressively narrower from width C to width D as it extends from surface  21  to its furthest extension at surface  29 . Furrow  28  corresponds in its dimensions, maintaining thickness A and thus the outer dimension of each ridge  27  is compatible with and insertable into a corresponding furrow  28  of a like or second unit  20  along its entire length between upper edge  23  and lower edge  24 . As demonstrated in FIGS. 7 and 8, the conformable dimensions of each ridge  27  and its corresponding furrow  28  allow various numbers of unit  10  to be stacked for shipping or storage, on or off site, with maximum handling and space efficiency. 
     Each wall panel support unit  20  in the preferred embodiment also has a flat recessed surface area  50  on its second exterior broad surface  22  and a corresponding flat protrusion  51  on the first exterior broad surface  21 . Recessed areas  50  and corresponding protrusion  51  are substantially in parallel, maintaining uniform thickness A of unit  20 , and both recessed area  50  and corresponding protrusion  51  run vertically between upper edge  23  and lower edge  24 , adjacent to second side edge  26 . As shown in the cross-sectional view of FIG. 2, recessed surface area  50  of unit  20  is configured to facilitate a mating with another, like, unit  20  by interfacing, by forming a common boundary therewith, with a corresponding area of the first exterior broad surface  21  of the like unit  20 , which corresponding area is adjacent to the first linear side edge  25  and runs vertically between upper edge  23  and lower edge  24  of the adjoining like unit  20 . 
     In the preferred embodiment of the invention a first series or plurality of pre-drilled holes or apertures  52  extending through thickness A between surface  21  and surface  22  are located on recessed area  50  and corresponding protrusion  51 , linearly aligned between upper edge  23  and lower edge  24  in parallel to second side edge  26 . A corresponding second series or plurality of pre-drilled holes or apertures  53 , running through thickness A between surface  21  and surface  22  is linearly aligned between upper edge  23  and lower edge  24 , adjacent and parallel to first side edge  25 . The first plurality of pre-drilled holes  52  and second plurality of pre-drilled holes  53  are configured and aligned so that each pre-drilled hole  52  in the first plurality and its corresponding pre-drilled hole  53  in the second plurality are linearly equidistant from upper edge  23  and lower edge  24  and are further configured and aligned so that when two units  20  are mated by interface between the recessed area  50  of one unit  20  and a portion of the first broad surface area  21  of a second unit  20  adjacent to the first side edge  23  of the second unit  20 , each pre-drilled hole  52  of the first unit  20  corresponds with a pre-drilled hole  53  of the second unit  20  so as to provide a continuous opening or aperture through the two interfaced units  20 , wherein the units may be mated by a plurality of fasteners  54  inserted through each pair of aligned pre-drilled holes  52  and  53 . In the preferred embodiment, each fastener  54  may be a screw, bolt, rivet or other fastening means. 
     In the preferred embodiment of the invention, in unit  20 , each uniform ridge  27  and corresponding uniform furrow  28  have a series or plurality of openings or apertures  55  linearly spaced between the upper edge  23  and lower edge  24 . A plurality of these openings  55  are located on the side of each ridge  28  between the planar linear surface  29  and first side edge  25  and a plurality of openings  55  are located on the side of each ridge  28  between the planar linear surface  29  and the second side edge  26 . These openings  55  may be utilized to pass electrical conduits, telephone or computer wire, other utilities or like purposes. 
     Upper track member  30  is constructed of a first rectangular bar element  31  and a second rectangular bar element  32 . First bar element  31  has an outward or exterior linear planar surface  33  and an interior linear planar surface  34 . Second bar element  32  has an outward or exterior linear planar surface  35  and an interior linear planar surface  36 . First bar element  31  and second bar element  32  are joined together linearly at right angles at a common edge  37 , so that the joined first bar element  31  and second bar element  32  form an L-shaped cross section. 
     Lower track member  40  is constructed of a first rectangular bar element  41  and a second rectangular bar element  42 . First bar element  41  has an outward or exterior linear planar surface  43  and an interior linear planar surface  44 . Second bar element  42  has an outward or exterior linear planar surface  45  and an interior linear planar surface  46 . First bar element  41  and second bar element  42  are joined together linearly at right angles at a common edge  47 , so that the joined first bar element  41  and second bar element  42  form an L-shaped cross section. 
     In the preferred embodiment of the invention, the outward linear planar surface  33  of the first bar element  31  track member  30  is configured to attach linearly to the ceiling  11  with the second bar element  32  extending downward at right angles from the ceiling along common edge  37 . 
     In the preferred embodiment of the invention, the outward linear planar surface  43  of the first bar element  41  of second track member  40  is configured to attach linearly to the floor  12  with the second bar element  42  extending upward at right angles from the floor along common edge  47 . 
     In a preferred embodiment of the invention, upper track member  30  and lower track member  40  additionally have, along their first rectangular bar elements  31  and  41 , respectively, a series of pre-drilled holes  60  which may be utilized in conjunction with a fastening means for affixing upper track  30  to the ceiling  11  and lower track  40  to the floor  12 , respectively, by passing fastening means through such pre-drilled holes, or apertures  60 . 
     In the preferred embodiment of the invention, upper track member  30  and lower track member  40  additionally have a series or plurality of apertures consisting of pre-drilled holes  61  extending through second bar elements  32  and  42 , respectively, and aligned linearly along the length of bar elements  32  and  42  respectively. Each support unit  20  further has a pair of series of pre-drilled holes  62  running between first broad surface area  21  and second broad surface areas  22 , with a first series thereof linearly aligned and adjacent to upper edge  23  and running between side edge  25  and side edge  26  and a second series thereof linearly aligned and adjacent to lower edge  24  and running between side edge  25  and side edge  26 . In the first series of pre-drilled holes  62  each hole  62  is located and configured to correspond with one or more of the pre-drilled holes  61  in upper support member  30  and in the second series of pre-drilled holes  62 , each hole  62  is located and configured with one or more of the pre-drilled holes  61  in the lower support member  40 , so that when one or more units  20  are placed against upper tracks  30  and  40 , they may be held in place by a fastening means  63  running through one or more of the aligned pre-drilled holes  61  and  62   
     Accordingly, the wall system assembly  10  includes a plurality or series of units  20 , affixed as stated, to a combination of an upper track member  30  and lower track member  40  arranged in vertical parallel, as set forth in FIG.  1 . 
     Whereas, a preferred embodiment of the invention has been illustrated and described in detail, it will be apparent that various changes may be made in the disclosed embodiment without departing from the spirit of the invention.