Composite wall system

Abstract

A composite wall assembly includes a frame. A sheathing layer of composite material is mounted on the frame. At least one waterproof insulating layer is adhered to the sheathing layer without puncturing the waterproof insulating layer. An outer layer of composite material is adhered to the waterproof insulating layer opposite the sheathing layer without puncturing the outer layer. The sheathing layer and the outer layer may be a magnesium oxide composite board material.

1 . A composite wall assembly comprising:
 a frame;   a sheathing layer of composite material mounted on said frame;   at least one waterproof insulating layer attached to said sheathing layer; and   an outer layer of composite material attached to said waterproof insulating layer opposite said sheathing layer;   wherein at least said outer layer of composite material is devoid of any puncture holes through said outer layer.   
   
   
       2 . The composite wall assembly of  claim 1 , wherein said sheathing layer is a magnesium oxide composite board material. 
   
   
       3 . The composite wall assembly of  claim 1 , wherein said waterproof insulating layer is a foam extruded polystyrene. 
   
   
       4 . The composite wall assembly of  claim 1 , wherein said outer layer is a magnesium oxide composite board material. 
   
   
       5 . The composite wall assembly of  claim 1 , wherein said sheathing layer is mounted on said frame by at least one of a plurality of mechanical fasteners and an adhesive. 
   
   
       6 . The composite wall assembly of  claim 1 , wherein said waterproof insulating layer and said outer layer are attached without forming puncture holes through said layers. 
   
   
       7 . The composite wall assembly of  claim 1 , wherein said frame includes a plurality of spaced studs disposed between first and second end members. 
   
   
       8 . The composite wall assembly of  claim 7 , wherein said studs are generally C-shaped and said end members are C-channels. 
   
   
       9 . The composite wall assembly of  claim 1 , wherein at least said outer layer of composite material is devoid of any mechanical fasteners which puncture through said outer layer. 
   
   
       10 . The composite wall assembly of  claim 9 , wherein the waterproof insulating layer is devoid of any mechanical fasteners which puncture through said outer layer. 
   
   
       11 . A composite wall system comprising:
 a first composite wall section including:
 a first frame; 
 a first sheathing layer of composite material mounted on said first frame; 
 a first waterproof insulating layer adhered to said first sheathing layer; and 
 a first outer layer of composite material adhered to said first waterproof insulating layer opposite said first sheathing layer, said first outer layer of composite material being devoid of any puncture holes through said first outer layer; 
   a second composite wall section including:
 a second frame; 
 a second sheathing layer of composite material mounted on said second frame; 
 a second waterproof insulating layer adhered to said second sheathing layer; and 
 a second outer layer of composite material adhered to said second waterproof insulating layer opposite said second sheathing layer, said second outer layer of composite material being devoid of any puncture holes through said second outer layer; 
   wherein said first composite wall section is connected to said second composite wall section through said first and second frames.   
   
   
       12 . The composite wall system of  claim 11 , wherein said first and second frames include a plurality of spaced studs; and
 said first composite wall section is connected to said second composite wall section by mechanical fasteners extending through one said stud of said first frame and one adjacently disposed stud of said second frame.   
   
   
       13 . The composite wall system of  claim 11 , wherein a seam between said first and second composite wall sections is sealed with a sealant adhesive. 
   
   
       14 . The composite wall system of  claim 11 , including a connector component disposed between and connected to said first and second composite wall sections, wherein said connector component includes:
 a connector frame;   a connector sheathing layer of composite material mounted on said connector frame;   a connector waterproof insulating layer adhered to said connector sheathing layer; and   a connector outer layer of composite material adhered to said connector waterproof insulating layer opposite said connector sheathing layer.   
   
   
       15 . The composite wall system of  claim 14 , wherein said connector component is one of a 90° elbow connector, a T-shaped connector, and a Z-shaped connector. 
   
   
       16 . The composite wall system of  claim 14 , wherein said first frame, said second frame, and said connector frame each include a plurality of spaced studs;
 said first composite wall section is connected to said connector component by mechanical fasteners extending through one said stud of said first frame and one adjacently disposed stud of said connector frame; and   said second composite wall section is connected to said connector component by mechanical fasteners extending through one said stud of said second frame and one adjacently disposed stud of said connector frame.   
   
   
       17 . The composite wall system of  claim 14 , wherein a seam between said first composite wall section and said connector component is sealed with a sealant adhesive, and a seam between said second composite wall section and said connector component is sealed with a sealant adhesive. 
   
   
       18 . The composite wall system of  claim 11 , wherein said first and second composite wall sections are erected on a concrete footing. 
   
   
       19 . The composite wall system of  claim 18 , including a waterproof membrane disposed between said footing and said first and second composite wall sections. 
   
   
       20 . The composite wall system of  claim 18 , wherein said first and second composite wall sections form walls of a basement. 
   
   
       21 . A method of assembling a composite wall comprising the steps of:
 constructing a frame including a plurality of spaced studs disposed between first and second end members;   mounting a sheathing layer of composite material on said frame with mechanical fasteners extending through said sheathing layer and said studs;   adhering at least one waterproof insulating layer to said sheathing layer without puncturing said waterproof insulating layer; and   adhering an outer layer of composite material to said waterproof insulating layer opposite said sheathing layer without puncturing said outer layer.   
   
   
       22 . The method of  claim 21 , wherein said sheathing layer and said outer layer are made of a magnesium oxide composite board material. 
   
   
       23 . A composite wall assembly comprising:
 a frame;   a sheathing layer of composite material mounted on said frame;   at least one waterproof insulating layer attached to said sheathing layer; and   an outer layer of composite material attached to said waterproof insulating layer opposite said sheathing layer;   wherein at least said outer layer of composite material is devoid of any mechanical fasteners which puncture through said outer layer.   
   
   
       24 . The composite wall assembly of  claim 23 , wherein the waterproof insulating layer is devoid of any mechanical fasteners which puncture through said outer layer.