CARGO SMART WALL

Abstract

A method for forming a structural wall section by sandwiching a corrugated metal panel between correspondingly corrugated EPS inner and outer panels. Also disclosed is a structural wall formed from a corrugated metal wall sandwiched between inner and outer EPS panels with a corrugated side on each of the EPS panels engaged with the corrugated metal panel.

Claims

1. A method of constructing a structural wall comprising the steps of: securing a planar panel of EPS, said panel having a width and length and height, with the length being the longest dimension, with an interior side and an external side, and a top edge, a bottom edge, a left edge and a right edge, said edges forming a perimeter around said panel; securing a metal panel, said panel having a width and length and height, with the length being the longest dimension, said panel having a metal panel interior side and a metal panel exterior side, and a metal panel top edge, a metal panel bottom edge, a metal panel left edge and a metal panel right edge, for forming an inner layer said structural wall; cutting said planar panel of EPS between said first and second side, with said cutting step forming a kerf comprised of a profile matching any flats and valleys and protrusions and depressions found on said metal panel, said cutting action forming an interior and an exterior panel for counter matching attachment to said interior side and said exterior side of said panel; attaching said interior panel of EPS to said interior side of said metal panel using an adhesive; and attaching said exterior panel of EPS to said exterior side of said metal panel using an adhesive, forming a structural wall.

2. The method of claim 1 in which said step of securing a metal panel further comprises securing a metal panel comprised of angular channels extending between said metal panel top edge and said metal panel bottom edge, with said channels forming corrugations on said metal panel interior and said metal panel exterior sides; with said step of cutting said EPS forming a kerf between said interior and exterior panels comprises cutting said kerf in a shape corresponding to said angular channels of said metal panel.

3. A method of constructing a structural wall comprising the steps of: securing a planar panel of EPS, said panel having a width and length and height, with the length being the longest dimension, with an interior side and an external side, and a top edge, a bottom edge, a left edge and a right edge, said edges forming a perimeter around said panel; securing a metal panel, said panel having a width and length and height, with the length being the longest dimension, said panel having a metal panel interior side and a metal panel exterior side, and a metal panel top edge, a metal panel bottom edge, a metal panel left edge and a metal panel right edge, for forming an inner layer said structural wall, said metal panel comprised of angular channels extending between said metal panel top edge and said metal panel bottom edge, with said channels forming corrugations on said metal panel interior and said metal panel exterior sides; cutting said planar panel of EPS between said first and second side, with cutting said EPS panel between said interior and exterior panels in a shape corresponding to said angular channels of said metal panel, with said cutting forming a kerf comprised of a profile matching any flats and valleys and protrusions and depressions found on said metal panel, said cutting action forming an interior and an exterior EPS panel for contour matching engagement and attachment to said interior side and said exterior side of said metal panel; attaching said interior panel of EPS to said interior side of said metal panel using an adhesive; and attaching said exterior panel of EPS to said exterior side of said metal panel using an adhesive, forming a structural wall.

4. The method of constructing a structural wall of claim 3 which further comprises the step of using a corrugated metal wall of a shipping container as the metal panel, combined with the steps of securing an panel of EPS, cutting down the middle to match the corrugations of said metal panel, and attaching said interior panel and exterior panel of EPS to said metal panel interior and said metal panel exterior side.

5. A method of constructing a structural wall comprising the steps of: securing a planar first panel of EPS, said panel having a width and length and height, with the length being the longest dimension, with a first panel of EPS interior side with corrugations corresponding to corrugations of a metal panel interior side, and an external side of said first panel of EPS with a planar surface, said first panel of EPS with a top edge, a bottom edge, a left edge and a right edge, said edges forming a perimeter around said panel; securing a planar second panel of EPS, said panel having a width and length and height, with the length being the longest dimension, with a second panel of EPS interior side with corrugations corresponding to corrugations of a metal panel exterior side, and an external side of said second of EPS with a planar surface, said second panel of EPS with a top edge, a bottom edge, a left edge and a right edge, said edges forming a perimeter around said second panel; securing a metal panel, said panel having a width and length and height, with the length being the longest dimension, said panel having a metal panel interior side and a metal panel exterior side, and a metal panel top edge, a metal panel bottom edge, a metal panel left edge and a metal panel right edge, for forming an inner layer said structural wall, said metal panel comprised of angular channels extending between said metal panel top edge and said metal panel bottom edge, with said channels forming corrugations on said metal panel interior and said metal panel exterior sides; attaching said interior panel of EPS to said interior side of said metal panel using an adhesive; and attaching said exterior panel of EPS to said exterior side of said metal panel using an adhesive, forming a structural wall.

6. The method of constructing a structural wall of claim 3 which further comprises the step of using a corrugated metal wall of a shipping container as the metal panel, combined with the steps of securing a first and second panel of EPS, each with corrugations to match those of said metal panel, and attaching said first EPS and second EPS panel to said metal panel interior and said metal panel exterior side, thus forming a three layer structural wall without internal voids.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] FIG. 1 is a top view of the structural wall.

[0017] FIG. 2 is a top view of the assembled structural wall.

[0018] FIG. 3 is a top front perspective of a partial assembled view of the interior panel coupled to the metal panel.

[0019] FIG. 4 is a top view of the planar panel of EPS.

[0020] FIG. 5 is a top view of the step of cutting profile matching any flats and valleys and protrusions and depressions found on metal panel.

[0021] FIG. 6 is a top view of cutting planar panel of EPS.

[0022] FIG. 7 is a top view of a planar panel of EPS with kerf.

[0023] FIG. 8 is a top view of the interior side and external side of planar panel of EPS.

[0024] FIG. 9 is a top view of the step of securing planar panel of EPS to a wall.

[0025] FIG. 10 is a rear view of the step of securing planar panel of EPS to a wall where the wall is a shipping container.

[0026] FIG. 11 is a perspective view of a metal panel.

[0027] FIG. 12 is a perspective view of an external side.

[0028] FIG. 13 is a perspective view of an interior side.

DEFINITIONS

[0029] In the following description and in the figures, like elements are identified with like reference numerals.

[0030] The use of e.g., and or indicates non-exclusive alternatives without limitation unless otherwise noted.

[0031] The use of including means including, but not limited to, unless otherwise noted.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0032] While the presently disclosed inventive concept(s) is susceptible of various modifications and alternative constructions, certain illustrated embodiments thereof have been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to limit the inventive concept(s) to the specific form disclosed, but, on the contrary, the presently disclosed and claimed inventive concept(s) is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the inventive concept(s) as defined in the claims.

[0033] Certain preferred embodiments of the disclosed technology are shown in FIGS. 1 through 13.

[0034] Disclosed in FIG. 1 is a top view of the structural wall (10). In the preferred embodiment is the interior side (14) after it is cut and separated from the external side (16). The interior side (14) and the external side (16) originally come in one planar block of EPS (12). A kerf (38) is used to separate the planar block of EPS (12) into a first side (34) and a second side (36). The kerf (38) is shaped depending on the shape of the metal panel (18).

[0035] In the preferred embodiment, the metal panel (18) consists of a plurality of corrugations (66). The interior side (14) and the external side (16) are specifically cut to match the corrugations (66) of the metal panel (18). The interior side (14) is attached to the metal panel (18) using an internal adhesive (48). The external side (16) is attached to the metal panel (18) using an external adhesive (50). A siding adhesive (84) is used attach the outer side (16) with the decorative siding (82). The decorative siding (82) is generally flat and is the outermost surface of the structural wall (10) if used. The decorative siding (82) is an optional feature.

[0036] FIG. 2 is a top view of the assembled structural wall. Shown is the preferred embodiment of the step of securing the panel of EPS to a wall (70). Shown is the interior side (14) coupled with the metal panel (18), and the external side (16) to form the structural wall (10).

[0037] FIG. 3 is a top front perspective view of a partially assembled interior side (14) coupled to metal panel (18). In the preferred embodiment, the interior side (14) and the external side (16) which is not shown in FIG. 3 will appear flush with the metal panel (18). An interior adhesive (48) and an external adhesive (50) will be applied to the kerf (38) of each side and the metal panel (18). The interior adhesive (48) and the external adhesive (50) will couple the interior side (14) with the metal panel (18), and the external side (16) with the metal panel (18).

[0038] FIG. 4 is a top view of the planar panel of EPS. Shown is the planar panel (12) prior to cutting said planar of EPS (32) using a cutting tool (86). The cutting tool (86) can be a laser or hotwire, or any other means to cut EPS known in the industry.

[0039] FIG. 5 is a top view of the step of cutting (32) profile matching any flats (40) and valleys (42) and protrusions (44) and depressions (46) found on metal panel (18).

[0040] FIG. 6 is a top view of cutting the planar panel of EPS (32). In a preferred embodiment, the cutting tool (86) is moved through the inner surface of the planar panel (12) in a pattern matching the corrugations (66) of the metal panel (18).

[0041] FIG. 7 is a top view of a planar panel of EPS with kerf. Shown is the preferred embodiment, which displays the kerf (38) after the cutting tool (86) has cut the planar panel of EPS (12) which corresponds with the corrugations (66) of the metal panel (18). The planar panel of EPS (12) is now divided into an interior side (14) and an eternal side (16).

[0042] FIG. 8 is a top view of the interior side (14) and external side (16) of planar panel of EPS. The kerf (38) has divided the planar panel of EPS (12). The flats (40) and valleys (42) and protrusions (44) and depressions (46) match the metal panel (18) for which the planar panel of EPS (12) was designed.

[0043] FIG. 9 is a top view of the step of securing planar panel of EPS to a wall (70). In the preferred embodiment, the interior side (14) and the external side (16) are secured around a metal panel (18) using an internal adhesive (48) and an external adhesive (50) applied to the kerf (38) to form the structural wall (10).

[0044] FIG. 10 is a rear view of the step of securing planar panel of EPS to a wall (70) where the wall is a shipping container (80). In the preferred embodiment, the step of securing a first planar panel of EPS to a wall (72) and the step of securing a second planar panel of EPS to a wall (74) in combination where the wall is a metal panel (18) form the structural wall (10). Shown is the step of securing a first planar panel of EPS to a wall (72) and the step of securing a second planar panel of EPS to a wall (74) where the metal panel (18) is a shipping container wall (68).

[0045] FIG. 11 is a perspective view of a metal panel (18). Shown is the preferred embodiment displaying a metal panel interior side (20), metal panel exterior side (22), metal panel top edge (24), metal panel left edge (26), metal panel bottom edge (62), and a metal panel right edge (28). In the preferred embodiment there are corrugations (66) in the metal panel (18).

[0046] FIG. 12 is a perspective view of an external side (16). In the preferred embodiment, there is a left edge (56), right edge (58), top edge (52), and bottom edge (54). The edges for a perimeter (60).

[0047] FIG. 13 is a perspective view of an interior side (14). The kerf (38) is cut using the cutting tool (86) that match the corrugations (66) of the metal panel (18).