Wall system

Abstract

A wall panel is provided that can be prefabricated and pre-assembled, and can be easily and quickly installed in the field. The wall panel includes an exterior infill component, an interior structural component, and a frame. The frame includes a first jamb member, a second jamb member, a head member, and a sill member. A wall system is provided comprising a plurality of wall panels. A method of installing the wall panel system and a method of assembling the wall panel are also provided.

What is claimed is: 
     
         1 . An exterior load bearing wall panel, comprising:
 an exterior infill component;   an interior structural component connected to the exterior infill component; and   a frame connected to the interior structural component, the frame including a first jamb member, a second jamb member, a head member, and a sill member.   
     
     
         2 . The wall panel of  claim 1 , wherein the exterior infill component comprises a cladding component, a plurality of furring strips, and an insulation component. 
     
     
         3 . The wall panel of  claim 2 , wherein the cladding component is fiber cement cladding or metal panel cladding. 
     
     
         4 . The wall panel of  claim 2 , wherein the plurality of furring strips is galvanized steel channels. 
     
     
         5 . The wall panel of  claim 1 , wherein the interior structural component comprises a weather barrier, a structural sheathing component, and a structural frame. 
     
     
         6 . The wall panel of  claim 5 , wherein the structural frame comprises a bottom plate, a top plate, and a plurality of vertical studs. 
     
     
         7 . The wall panel of  claim 1 , wherein the frame is galvanized steel, aluminum, or vinyl. 
     
     
         8 . The wall panel of  claim 1 , wherein the first jamb member is at least one of a jamb extension and a first jamb angle. 
     
     
         9 . The wall panel of  claim 1 , wherein the second jamb member is at least one of a jamb receiver and a second jamb angle. 
     
     
         10 . The wall panel of  claim 1 , wherein the head member is at least one of a head extension, a head angle, and a T-shaped head extension. 
     
     
         11 . The wall panel of  claim 1 , wherein the sill member is at least one of a sill receiver, a sill angle, and a brake-formed sill receiver. 
     
     
         12 . The wall panel of  claim 1 , wherein the frame further includes a first corner, a second corner, a third corner, and a fourth corner. 
     
     
         13 . The wall panel of  claim 12 , wherein the first corner comprises a notched head extension and a notched jamb receiver, the second corner comprises a second notched head extension and a notched jamb extension, the third corner comprises a second notched jamb extension and a notched sill receiver, and the fourth corner comprises a second notched sill receiver and a second notched jamb receiver. 
     
     
         14 . An exterior load bearing wall panel system, comprising:
 a first wall panel;   a second wall panel;   a third wall panel; and   a fourth wall panel;   the first wall panel, the second wall panel, the third wall panel, and the fourth wall panel each including:
 an exterior infill component, 
 an interior structural component connected to the exterior infill component, and 
 a frame connected to the interior structural component, the frame including a first jamb member, a second jamb member, a head member, and a sill member; 
   the first wall panel and the second wall panel are aligned adjacently, the third wall panel and the fourth wall panel are aligned adjacently, the third wall panel is stacked on top of the first wall panel, and the fourth wall panel is stacked on top of the second wall panel;   the second jamb member of the first wall panel mates with the first jamb member of the second wall panel, the sill member of the third wall panel mates with the head member of the first wall panel, the second jamb member of the third wall panel mates with the first jamb member of the fourth wall panel, and the sill member of the fourth wall panel mates with the head member of the second wall panel.   
     
     
         15 . The wall panel system of  claim 14 , wherein the exterior infill component comprises a cladding component, a plurality of furring strips, and an insulation component. 
     
     
         16 . The wall panel system of  claim 15 , wherein the cladding component is fiber cement cladding or metal panel cladding. 
     
     
         17 . The wall panel system of  claim 15 , wherein the plurality of furring strips is galvanized steel channels. 
     
     
         18 . The wall panel system of  claim 14 , wherein the interior structural component comprises a weather barrier, a structural sheathing component, and a structural frame. 
     
     
         19 . The wall panel system of  claim 18 , wherein the structural frame comprises a bottom plate, a top plate, and a plurality of vertical studs. 
     
     
         20 . The wall panel system of  claim 14 , wherein the frame is galvanized steel, aluminum, or vinyl. 
     
     
         21 . The wall panel system of  claim 14 , wherein the first jamb member is at least one of a jamb extension and a first jamb angle. 
     
     
         22 . The wall panel system of  claim 14 , wherein the second jamb member is at least one of a jamb receiver and a second jamb angle. 
     
     
         23 . The wall panel system of  claim 14 , wherein the head member is at least one of a head extension, a head angle, and a T-shaped head extension. 
     
     
         24 . The wall panel system of  claim 14 , wherein the sill member is at least one of a sill receiver, a sill angle, and a brake-formed sill receiver. 
     
     
         25 . The wall panel system of  claim 14 , further comprising a gasket between the second jamb member of the first wall panel and the first jamb member of the second wall panel, a second gasket between the second jamb member of the third wall panel and the first jamb member of the fourth wall panel. 
     
     
         26 . The wall panel system of  claim 14 , further comprising a third gasket between the head member of the first wall panel and the head member of the second wall panel. 
     
     
         27 . The wall panel system of  claim 14 , further comprising a fourth gasket between the head member of the first wall panel and the sill member of the third wall panel and a fifth gasket between the head member of the second wall panel and the sill member of the fourth wall panel. 
     
     
         28 . The wall panel system of  claim 14 , further comprising silicone tape over the head member of the first wall panel and the head member of the second wall panel. 
     
     
         29 . A method of installing an exterior load bearing wall panel system, comprising:
 receiving a first wall panel, a second wall panel, a third wall panel, and a fourth wall panel, the first wall panel, the second wall panel, the third wall panel, and the fourth wall panel each including:
 an exterior infill component, 
 an interior structural component connected to the exterior infill component, and 
 a frame connected to the interior structural component, the frame including a first jamb member, a second jamb member, a head member, and a sill member; 
   installing the first wall panel;   installing the second wall panel by placing the first jamb member of the second wall panel along the second jamb member of the first wall panel;   stacking the third wall panel on top of the first wall panel by placing the sill member of the third wall panel along the head member of the first wall panel; and   stacking the fourth wall panel on top of the second wall panel by placing the first jamb member of the fourth wall panel along the second jamb member of the third wall panel and placing the sill member of the fourth wall panel over the head member of the second wall panel.   
     
     
         30 . The method of  claim 29 , further comprising installing gaskets between the second jamb member of the first wall panel and the first jamb member of the second wall panel and between the second jamb member of the third wall panel and the first jamb member of the fourth wall panel. 
     
     
         31 . The method of  claim 29 , further comprising installing gaskets between the head member of the first wall panel and the head member of the second wall panel. 
     
     
         32 . The method of  claim 29 , further comprising installing gaskets between the head member of the first wall panel and the sill member of the third wall panel and between the head member of the second wall panel and the sill member of the fourth wall panel. 
     
     
         33 . The method of  claim 29 , further comprising installing silicone tape over the head member of the first wall panel and the head member of the second wall panel. 
     
     
         34 . A method of assembling an exterior load bearing wall panel, comprising:
 receiving an exterior infill component, an interior structural component, and a frame, the frame including a first jamb member, a second jamb member, a head member, and a sill member;   connecting the frame to the interior structural component; and   connecting the exterior infill component to the interior structural component.   
     
     
         35 . The method of  claim 34 , wherein the exterior infill component comprises a cladding component, a plurality of furring strips, and an insulation component, and the interior structural component comprises a weather barrier, a structural sheathing component, and a structural frame. 
     
     
         36 . The method of  claim 35 , further comprising:
 attaching the structural sheathing component to the structural frame;   attaching the weather barrier to the structural sheathing;   attaching the frame to the structural sheathing;   attaching the insulation component to the weather barrier with the plurality of furring strips;   attaching the plurality of furring strips to the structural sheathing; and   attaching the cladding component to the plurality of furring strips.