Insulated construction panel and method

Claim 2

A construction panel which comprises: an interior stud frame including a bottom plate, a top plate, and at least one vertical stud extending between and connecting with the bottom and top plates; an exterior stud frame including a bottom plate, a top plate, and at least one vertical stud extending between and connecting with the bottom and top plates; an intermediate, rigid insulating material, said insulating material including an interior side and an exterior side, the interior side defining recesses in which the at least one vertical stud of said interior stud frame is at least partially received, the exterior side defining recesses in which the at least one vertical stud of said exterior stud frame is at least partially received; and, attachment means for attaching said interior frame through said insulating material to said exterior frame.

Claim 3

The construction panel of claim 1 in which said interior and exterior stud frames and said insulating material have one vertical end defining a groove portion and an opposite vertical end defining a tongue portion.

Claim 4

The construction panel of claim 1 and which is rectangular.

Claim 5

The construction panel of claim 3 in which said interior and exterior stud frames and said insulating material have one vertical end defining a groove portion and an opposite vertical end defining a tongue portion.

Claim 6

The construction panel of claim 1 in which said insulating material extends upwardly above the top plates of said interior and exterior stud frames.

Claim 7

The construction panel of claim 5 in which said interior and exterior stud frames and said insulating material have one vertical end defining a groove portion and an opposite vertical end defining a tongue portion.

Claim 8

The construction panel of claim 1 in which each of said interior and exterior stud frames includes at least two vertical studs extending between and connecting with the respective top and bottom plates, the interior side defining recesses in which the at least two vertical studs of said interior stud frame are at least partially received, the exterior side defining recesses in which the at least two vertical studs of said exterior stud frame are at least partially received.

Claim 9

The construction panel of claim 1 in which said interior and exterior stud frames and said insulating material have one vertical end defining a tongue portion and an opposite vertical end defining a second tongue portion.

Claim 10

The construction panel of claim 1 in which said interior and exterior stud frames and said insulating material have one vertical end defining a flat surface and an opposite vertical end defining a groove portion.

Claim 11

The construction panel of claim 1 and which further defines a window opening.

Claim 12

The construction panel of claim 1 and which further defines a door opening.

Claim 13

The construction panel of claim 1 in which said interior frame extends upwardly less than said exterior frame.

Claim 14

The construction panel of claim 12 in which said interior frame extends upwardly less than said exterior frame by a predetermined distance approximately equal to the height of a floor joist.

Claim 15

The construction panel of claim 12 and which further defines a window opening.

Claim 16

The construction panel of claim 12 and which further defines a door opening.

Claim 17

The construction panel of claim 1 in which said insulating material is planar and defines interior and exterior planar surfaces, said insulating material being rectangular in configuration and having vertical edges and horizontal edges; the interior surface of said insulating material defining a vertically extending recess spaced inwardly of the vertical edges and within which the at least one vertical stud of said interior stud frame is at least partially received, whereby the at least one vertical stud of said interior frame extends at least partially into said insulating material beyond the planar surface, the exterior surface of said insulating material defining a vertically extending recess spaced inwardly of the vertical edges and within which the at least one vertical stud of said exterior stud frame is at least partially received, whereby the at least one vertical stud of said exterior frame extends at least partially into said insulating material beyond the planar surface.

Claim 18

The construction panel of claim 16 in which each of said interior and exterior stud frames are planar; the at least one vertical stud of each of said interior and exterior stud frames having an interior surface for facing said insulating material and an exterior surface for facing outwardly from said insulating material; the interior side of said insulating material defining a recess within which the at least one vertical stud of said interior stud frame is fully received to have the exterior surface of the at least one vertical stud being co-plannar with the interior surface of said insulating material; the exterior side of said insulating material defining a recess within which the at least one vertical stud of said exterior stud frame is fully received to have the exterior surface of the at least one vertical stud being co-planar with the exterior surface of said insulating material.

Claim 19

A construction wall which comprises: a first construction panel having a first interior stud frame including a bottom plate, a top plate, and at least one vertical stud extending between and connecting with the bottom and top plates, a first exterior stud frame including a bottom plate, a top plate, and at least one vertical stud extending between and connecting with the bottom and top plates, a first intermediate, rigid insulating material, said insulating material including an interior side and an exterior side, the interior side defining recesses in which the at least one vertical stud of said first interior stud frame is at least partially received, the exterior side defining recesses in which the at least one vertical stud of said first exterior stud frame is at least partially received, and first attachment means for attaching said first interior frame through said first insulating material to said first exterior frame; a second construction panel having a second interior stud frame including a bottom plate, a top plate, and at least one vertical stud extending between and connecting with the bottom and top plates, a second exterior stud frame including a bottom plate, a top plate, and at least one vertical stud extending between and connecting with the bottom and top plates, a second intermediate, rigid insulating material, said insulating material including an interior side and an exterior side, the interior side defining recesses in which the at least one vertical stud of said second interior stud frame is at least partially received, the exterior side defining recesses in which the at least one vertical stud of said second exterior stud frame is at least partially received, and second attachment means for attaching said second interior frame through said second insulating material to said second exterior frame; the first interior and exterior stud frames and the first insulating material of said first construction panel having one vertical end defining a groove portion, the second interior and exterior stud frames and the second insulating material of said second construction panel having one vertical end defining a tongue portion, the tongue portion of said second construction panel being received within the groove portion of said first construction panel with the first insulating material abutting the second insulating material; and, connecting means for connecting said first construction panel with said second construction panel.

Claim 20

A construction wall which comprises: a first construction panel having a first interior stud frame including a bottom plate, a top plate, and at least one vertical stud extending between and connecting with the bottom and top plates, a first exterior stud frame including a bottom plate, a top plate, and at least one vertical stud extending between and connecting with the bottom and top plates, a first intermediate, rigid insulating material, said insulating material including an interior side and an exterior side, the interior side defining recesses in which the at least one vertical stud of said first interior stud frame is at least partially received, the exterior side defining recesses in which the at least one vertical stud of said first exterior stud frame is at least partially received, and first attachment means for attaching said first interior frame through said first insulating material to said first exterior frame; a second construction panel having a second interior stud frame including a bottom plate, a top plate, and at least one vertical stud extending between and connecting with the bottom and top plates, a second exterior stud frame including a bottom plate, a top plate, and at least one vertical stud extending between and connecting with the bottom and top plates, a second intermediate, rigid insulating material, said insulating material including an interior side and an exterior side, the interior side defining recesses in which the at least one vertical stud of said second interior stud frame is at least partially received, the exterior side defining recesses in which the at least one vertical stud of said second exterior stud frame is at least partially received, and second attachment means for attaching said second interior frame through said second insulating material to said second exterior frame; the first interior and exterior stud frames and the first insulating material of said first construction panel having one vertical end defining a groove portion, the second interior and exterior stud frames and the second insulating material of said second construction panel having one vertical end defining a tongue portion, the tongue portion of said second construction panel being received within the groove portion of said first construction panel with the first insulating material abutting the second insulating material; and, connecting means for connecting said first construction panel with said second construction panel.

Claim 21

The construction wall of claim 18 and which further includes at least one second top plate extending over and connecting with a top plate of said first construction panel and a top plate of said second construction panel.

Claim 22

The construction wall of claim 19 and in which the insulating material of each of said first and second construction panels extends upwardly above at least one of the top plates of each of said construction panels, the second top plate extending over and connecting with the at least one top plate of each of said first and second construction panels, the insulating material extending at least as high as the second top plate.

Claim 23

The construction wall of claim 20 in which the insulating material of said first construction panel extends upwardly above the top plates of both the interior and exterior stud frames of said first construction panel, the insulating material of said second construction panel extending upwardly above the top plates of both the interior and exterior stud frames of said second construction panel, said construction wall further including two second top plates, one of the second top plates extending over and being connected to the top plates of the interior stud frames of said first and second construction panels, the other of the second top plates extending over and being connected to the top plates of the exterior stud frames of said first and second construction panels, the insulating material of each of said first and second construction panels extending at least as high as the second top plates.