Prefabricated wall apparatus and method

Abstract

A prefabricated wall module may include framing members and one or more insulations members. The insulation member may have pre-incisions, as made by a hot-wire, defining service fitting accommodations. The service fitting accommodations are accessible on the inside face of the insulation. The service fitting accommodations may be either or both of vertically or laterally extending, and are located in the same places in each module, the vertical locations being next to the studs, to which service fittings may typically be mounted, the lateral accommodations being at heights typical of switches and wall outlets. The insulation members may be supplied with tabs filling the accommodations. The tabs may be snapped out as required. The insulation members may have stud channels that are shallower than the studs, such that an air gap is established between the insulation and the internal gypsum board covering.

1 .- 27 . (canceled) 
     
     
         28 . An insulation member sized to co-operate with framing studs, said insulation member having a height direction, a width direction, and a through-thickness direction, said insulation member being large in each of said height direction and said width direction than in said through-thickness direction, and wherein:
 said insulation member has a first surface and an opposed second surface, each of said first surface and said second surface extending in the directions of the height and width;   said insulation member having a portion thereof connected thereto by a frangible neck;   said portion running along said first surface;   when said neck is unbroken, said portion being secured in a fixed position;   when said neck is broken, said portion being removable to leave a chase running along said first surface of said insulation member, an exposed side of said chase being open, whereby to permit service fittings to be laid sideways into said chase.   
     
     
         29 . The insulation member of  claim 28  wherein said portion defines an insulation blank, and, when said neck is unbroken, said blank occupies said chase. 
     
     
         30 . The insulation member of  claim 29  wherein, when said neck is unbroken, said portion lies flush with said first surface. 
     
     
         31 . The insulation member of  claim 29  wherein said portion runs along an edge of said first surface. 
     
     
         32 . The insulation member of  claim 29  wherein said portion runs width-wise across said first surface. 
     
     
         33 . The insulation member of  claim 29  wherein said portion is a first said portion, and said insulation member includes a second portion running along said first surface, said second portion also being connected to said insulation member by a frangible neck. 
     
     
         34 . The insulation member of  claim 33  wherein said first portion runs parallel to said second portion along said first surface. 
     
     
         35 . The insulation member of  claim 33  wherein said first portion runs length-wise along said first surface, and said second portion runs width-wise along said surface. 
     
     
         36 . The insulation member of  claim 29  wherein said insulation member defines a plug for insertion between framing studs, and said second surface is of greater extent than said first surface, said second surface defining a head larger than said plug. 
     
     
         37 . The insulation member of  claim 36  wherein said plug has a through-thickness depth smaller than the framing studs, whereby, when installed, said first surface of said insulated member lies shy of said framing studs. 
     
     
         38 . The insulation member of  claim 36  wherein said insulation member has an edge portion running in the height direction therealong, and said edge portion includes a member connected thereto by a frangible neck, and, when said neck is broken said member of said edge portion is removable to leave at least a portion of a stud accommodation. 
     
     
         39 . The insulation member of  claim 29  wherein said insulation member includes a stud accommodation channel formed therein running in the height direction, said channel having a width corresponding to a stud width, and extending a majority of the way through the through-thickness of said insulation member. 
     
     
         40 . An insulation member sized to co-operate with framing studs, said insulation member having a height direction, a width direction, and a through-thickness direction, said insulation member being large in each of said height direction and said width direction than in said through-thickness direction, and wherein:
 said insulation member has a first surface and an opposed second surface, each of said first surface and said second surface extending in the directions of the height and width;   said insulation member having a portion thereof connected thereto by a frangible neck, said portion running in the height direction;   when said neck is unbroken, said portion being secured in a fixed position;   when said neck is broken, said portion being removable to leave a stud accommodation running along said first surface of said insulation member, an exposed side of said stud accommodation being open.   
     
     
         41 . The insulation member of  claim 40  wherein said portion runs along an edge of said insulation member. 
     
     
         42 . The insulation member of  claim 40  wherein said insulation member has a stud channel formed amidst said first surface, and said portion runs along an edge of said insulation member distant therefrom. 
     
     
         43 . The insulation member of  claim 40  wherein said insulation member has a further frangible portion that, when snapped, leaves a chase running along said first surface of said insulated member. 
     
     
         44 . The insulation member of  claim 43  wherein said chase runs alongside a stud accommodation of said insulation member. 
     
     
         45 . The insulation member of  claim 43  wherein said chase runs width-wise across said first surface. 
     
     
         46 . An insulation member sized to co-operate with framing studs, said insulation member having a height direction, a width direction, and a through-thickness direction, said insulation member being large in each of said height direction and said width direction than in said through-thickness direction, and wherein:
 said insulation member has a first surface and an opposed second surface, each of said first surface and said second surface extending in the directions of the height and width, and being separated from each other in said through-thickness direction;   said insulation member having at least one stud accommodation formed along an edge running in the height direction;   said insulation member having a main body portion and a first portion connected to said main body portion by a frangible neck;   said first portion running along said first surface;   when said neck is unbroken, said first portion being secured in a fixed position relative to said main body;   when said neck is broken, said first portion being removable to leave a chase running along said first surface of said insulation member, an exposed side of said chase being open, whereby to permit service fittings to be laid sideways into said chase.   
     
     
         47 . The insulation member of  claim 46  wherein:
 said insulation member having a second portion thereof connected to said main body by a frangible neck, said second portion running in the height direction; 
 when said neck is unbroken, said second portion being secured in a fixed position; 
 when said neck is broken, said second portion being removable to leave a stud accommodation running along said first surface of said insulation member, an exposed side of said stud accommodation being open.