Rigid wall panel system

Abstract

The invention is a prefabricated rigid wall panel assembly constructed of a plurality of C-shaped studs inserted into kerfs in a foam block. The closed ends of the C-shaped studs and the foam block form substantially planar longitudinal edges of the panel assembly capable of abutting an adjacent panel assembly. Optionally, a header and/or footer plate inserted is into a transverse kerf such that the plate overlaps the ends of the studs, and the header and/or footer plate and the foam block form a substantially planar transverse edge of the panel assembly. Adjacent panel assemblies are preferably secured to one another using a clip, the shape of which depends on the angle at which the panel assemblies abut. Each panel assembly may also have a wire chase.

1 . A rigid wall panel assembly comprising:
 a foam block having a center, an exterior surface, and an interior surface;   a plurality of longitudinal kerfs spaced across the interior surface of the foam block that do not puncture the exterior surface of the foam block; and   a plurality of C-shaped studs having an open edge and a closed edge wherein a portion of the C-shaped studs are located within the longitudinal kerfs, and wherein two of C-shaped studs are oriented with respect to the foam block such that the open edge of the two C-shaped studs are oriented towards the center of the foam block, and wherein the closed edge of the two C-shaped studs and the foam block form two substantially planar longitudinal edges of the rigid wall panel assembly.   
   
   
       2 . The rigid wall panel assembly of  claim 1 , further comprising:
 a transverse kerf in the foam block;   a U-shaped top/bottom plate having an open edge and a closed edge, wherein a portion of the U-shaped top/bottom plate is located within the transverse kerf, and wherein the U-shaped top/bottom plate is oriented with respect to the foam block such that the open edge of the U-shaped top/bottom plate is directed towards the center of the foam block, and wherein the closed edge of the U-shaped top/bottom plate and the foam block form at least one substantially planar transverse edge of the rigid wall panel assembly.   
   
   
       3 . The rigid wall panel assembly of  claim 1 , further comprising one or more wire chases within a recess between a wallboard mounted to the studs and an interior surface of the foam block. 
   
   
       4 . A wall, comprising a plurality of adjacent rigid wall panel assemblies, each rigid wall panel assembly further comprising:
 a foam block having a center, an exterior surface, and an interior surface;   a plurality of longitudinal kerfs spaced across the interior surface of the foam block that do not puncture the exterior surface of the foam block; and   a plurality of C-shaped studs having an open edge and a closed edge wherein a portion of the C-shaped studs are located within the longitudinal kerfs, and wherein two of C-shaped studs are oriented with respect to the foam block such that the open edge of the two C-shaped studs are oriented towards the center of the foam block, and wherein the closed edge of the two C-shaped studs and the foam block form two substantially planar longitudinal edges of the rigid wall panel assembly.   
   
   
       5 . The wall of  claim 4 , each rigid wall panel assembly further comprising:
 a transverse kerf in the foam block;   a U-shaped top/bottom plate having an open edge and a closed edge, wherein a portion of the U-shaped top/bottom plate is located within the transverse kerf, and wherein the U-shaped top/bottom plate is oriented with respect to the foam block such that the open edge of the U-shaped top/bottom plate is directed towards the center of the foam block, and wherein the closed edge of the U-shaped top/bottom plate and the foam block form at least one substantially planar transverse edge of the rigid wall panel assembly.   
   
   
       6 . The wall of  claim 4  wherein the longitudinal edges of adjacent rigid wall panel assemblies abut along a plane. 
   
   
       7 . The wall of  claim 4  wherein the longitudinal edges of adjacent rigid wall panel assemblies abut along a plane, further comprising one or more parallel clips having tabs formed to engage the open edge of two of the C-shaped studs forming the longitudinal edges of adjacent rigid wall panel assemblies. 
   
   
       8 . The wall of  claim 4  wherein the longitudinal edges of adjacent rigid wall panel assemblies abut along a line.
 The wall of  claim 4  wherein the longitudinal edges of adjacent rigid wall panel assemblies abut along a line, further comprising one or more angled clips having tabs formed to engage the open edge of two of the C-shaped studs forming the longitudinal edges of adjacent rigid wall panel assemblies.