US20100269439A1 - Insulated panel and system for construction of a modular building and method of fabrication thereof - Google Patents

Abstract

An insulated wall panel, comprises a polystyrene foam block having first and second parallel surfaces, top and bottom parallel ends and two parallel side ends, wherein the block is configured to include slots to receive a plurality of studs spaced apart and in parallel relation to one another within the block between the first and second surfaces and the two side ends so that side surfaces of the studs are not exposed. The panel may also include a first track member that is secured to a slab or building foundation and to a bottom end of the studs, and a second track member that is mounted to a top end of the studs.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
• This application claims the benefit of U.S. Provisional Application No. 61/173,231 filed Apr. 28, 2009, and incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
• Embodiments of the subject invention pertain to building frames for construction of modular buildings. More specifically, the embodiments of the subject invention pertain to the assembly of insulated panels used to construct modular buildings, which panels include a plurality of studs or frame members imbedded or inserted in expanded polystyrene blocks configured or adapted to receive the studs or frame members.
• The use of polymer foam panels in building construction is known. With respect to U.S. Pat. No. 5,822,940 (the “'940 Patent”), there is disclosed a wall panel that includes a polymer foam block in which studs are imbedded. The foam block is configured to include a plurality of slots for receiving generally C-shaped studs; however, as shown in FIG. 33BB of the '940 Patent, the slots are formed in the foam block in such a manner that surfaces of the studs are exposed. Such a configuration may unnecessarily expose the foam block to ambient conditions. Accordingly, need exists for a wall panel constructed from a polymer foam material in which the studs are effectively sealed and/or embedded within the foam block so surfaces of the studs are not exposed.
BRIEF DESCRIPTION OF THE INVENTION
• An embodiment of the invention for an insulated wall panel comprises a polystyrene foam block having first and second parallel surfaces, top and bottom parallel ends and two parallel side end. The block is configured to include slots to receive a plurality of studs, and each stud having a generally C-shaped configuration including a web and flanges perpendicular to the web and parallel to one another and the flanges having side surfaces. The studs are spaced apart and in parallel relation to one another within the block between the first and second surfaces and the two side ends of the block so that side surfaces of the flanges on the studs and the webs on the studs are not exposed.
• In an embodiment the insulated wall panel may comprise a polystyrene foam block having first and second parallel surfaces, top and bottom parallel ends and two parallel side ends. The block is configured to include slots to receive a plurality of studs spaced apart and in parallel relation to one another within the block between the first and second surfaces and the two side ends. A first track member has a web member secured to a building foundation and two spaced apart vertically disposed flanges that are secured to bottom ends of the studs. The block has channels formed in the bottom end thereof spaced apart and parallel to one another in which the flanges of the first track member are inserted. In addition, an elongated recess is formed in the bottom of the block between the channels and extending from one side end to the other side end, and the web of the first track member is positioned in the elongated recess. The block also comprises parallel flanges at the bottom end thereof on either side of the recess that cover the flanges of the first track member.
• A second track member is provided and has a web member and two spaced apart vertically disposed flanges and the block has channels formed in the top end thereof spaced apart and parallel to one another in which the flanges of the second track member are inserted and secured to top ends of the studs. In addition, an elongated recess is formed in the top of the block between the channels and extending from one side end to the other side end of the block and the web of the first track member is positioned in the elongated recess, and the block has parallel flanges at the top end thereof on either side of the recess that cover the flanges of the second track member.
• An embodiment of the invention may be described as a wall system that includes a plurality of the above-described wall panels and the studs for each wall panel are spaced inward of each side end of a respective block forming an extension on the blocks at each side end thereof wherein a notch is formed in an extension of each respective block. The notch extends from the bottom end to the top end of each block so that when two wall panels having notches therein are positioned side end to side end a volume is formed between the notches and an insert, having a configuration corresponding to a configuration of the volume, is inserted in the volume to connect the panels.
• The insulated wall panel system further comprises two corner wall panels that each include two double stud assemblies and each stud assembly is disposed at a respective side ends of each of the foam blocks of the wall panels, and there being a plurality of studs disposed within each block and between the double stud assemblies. Each double stud assembly has a generally I-shaped configuration with a web and two spaced apart flanges that are parallel to one another and perpendicular to the web. Each side end of each block for a respective corner wall panel is cut to include a recess extending the height of the respective side end and to include two slots contiguous with the recess, perpendicular to the recess and parallel to one another, wherein a web of the double stud assembly is seated in the recess and flanges of the double stud assembly are seated in the slots. The two corner panels are secured to a foundation perpendicular to one another forming a corner of a building frame and the double stud assembly for each wall panel. The respective web members thereof are disposed perpendicular to one another and a bracket, having been secured to the foundation, includes a base plate secured to the foundation and two vertically disposed plates perpendicular to one another extending upward from the base plate, and wherein each vertically disposed plate is secured to a web of a respective double stud assembly.
• An embodiment of the invention for a method of assembling an insulated wall panel, comprises providing a polystyrene foam block having first and second parallel surfaces, top and bottom parallel ends and two parallel side ends; cutting a series of spaced apart slots into the block between the side ends of the block and parallel to one another, and the slots extend from the bottom end of the block to the top end of the block and wherein each slot includes a first slot is parallel to the side ends of the block and two second slots that are contiguous with the first slot and the second slots are parallel to one another and perpendicular to the first slot and within the parallel surfaces of the block; cutting into the bottom end of the block a first pair of channels that are spaced apart and parallel to one another and extend from one side end to the other side end of the block, wherein the first pair of channels are contiguous with the second slots; cutting into the top end of the block a second pair channels that are spaced apart and parallel to one another and extend from one side end to the other side end of the block, wherein the second pair of channels are contiguous with the second slots; cutting into the bottom end of the block an elongated first recess between the first pair of channels, wherein the first recess extends from one side end of the block to the other side end of the block; cutting into the top end of the block an elongated second recess between the second pair of channels, wherein the second recess extends from one side end of the block to the other side end of the block; and, inserting a stud into each of the slots of the series of slots wherein each stud has a generally C-shaped configuration including a web member and two flanges parallel to one another and perpendicular to the web member, wherein the web member of a stud is inserted in the first slot and the flanges of a stud are inserted into the second slots.
BRIEF DESCRIPTION OF THE DRAWINGS
• A more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not, therefore, to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings.
• FIG. 1 is an elevational view of an insulated construction or wall panel and its components.
• FIG. 2 is a top end view of the panel shown inFIG. 1.
• FIG. 3 is an end view of the panel shown inFIG. 1.
• FIG. 4 is a perspective end view of a stud used in the panel shown inFIGS. 1 and 2.
• FIG. 5 is a perspective partial end view of polystyrene foam block having been cut to receive studs.
• FIG. 6 is a partial end view of the bottom of an insulated construction panel including a bottom track member.
• FIG. 7 is a partial end view of the top of an insulated construction panel including a top track member.
• FIG. 8 is an exploded view of two insulated construction panels.
• FIG. 9 is an elevational view of insulated shear panel assembly.
• FIG. 10 is a top view of the shear panel assembly shown inFIG. 9.
• FIG. 11 is a perspective partial end view of polystyrene foam block material having been cut to assembly a shear panel assembly.
• FIG. 12 is a perspective partial end view of the assembled shear panel.
• FIG. 13 is a corner assembly including two shear panel assemblies.
• FIG. 14A is a top view of a corner bracket used for installing a corner assembly.
• FIG. 14B is an elevational view of the bracket shown inFIG. 14A.
• FIG. 15A is a top view of a bracket used for securing an end of a shear panel assembly.
• FIG. 15B is an elevational view of the bracket shown inFIG. 15A.
• FIG. 16 is an alternative corner assembly of two shear panel assemblies.
DETAILED DESCRIPTION OF THE INVENTION
• A more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained.
• With respect toFIG. 1 there is shown aninsulated wall panel10 including ablock11 of a composite material such as expanded polystyrene foam or Styrofoam adapted for receivingmetal studs12 to construct a modular building frame. For purposes of describing the invention reference is made to a wall panel but the system or method disclosed herein may be used to construct other frame members such as floor and ceiling joists, and is not limited to a wall panel, either interior or exterior. The foam panel manufactured by Insulfoam may be used to assemble thewall panels10 disclosed herein.
• As shown thewall panel10 includes or is secured to abottom track13A frame member that is mounted to afoundation slab14 for receiving and securing thestuds12 and thefoam block11 onto theslab14. In addition, atop track13B frame member is mounted to thewall panel10 as will be explained in more detail below; or, thewall panel10 may be described as including thetop track13B frame member. Both thetop track member13B andbottom track member13A supplemental the structural integrity of thepanel10, and thetop track13B provides a mechanism for securing other frame members to thepanel10.
• With reference to the assembly of thewall panel10, thefoam block11 is first cut according to building specifications on a hotwire cutting apparatus that is used for cutting and shaping Styrofoam. As shown inFIGS. 1,2 and3 theblock11 includes afirst wall surface15A and asecond wall surface15B, abottom end17A andtop end17B and two side ends34A and34B. In addition, thefoam block11 has predetermined height H, length L and width W dimensions. Thefoam block11 is secured on a table associated with a hotwire cutting apparatus which includes a controller that is configured or programmed to transmit signals so that heated wires mounted on the apparatus cut the foam according to building specification data input into the database and/or program for operation of the hotwire cutting apparatus. The hot wire cutting apparatus may have a single wire that cuts the slots27 (shownFIG. 5) spaced apart in theblock11 for receiving thestuds12; or the cutting apparatus may include a plurality of wires that may simultaneously cut a plurality of theslots27 at predetermined spaced intervals.
• Asample stud12 is illustrated inFIG. 4 and has a generally C-shaped configuration including aweb12A,first flanges12B disposed perpendicular to theweb12A and returns12C that are parallel to theweb12A. A representative cut is in ablock11 for insertion of studs is shown inFIG. 5. A wire enters theblock11 from oneside15A or15B of theblock11 and descends downward toward theother side15A or15B of theblock11. The hotwire moves and cuts theblock11 responsive to commands from a controller in predeterminedpattern forming slots27A,27B and27C corresponding to theparts12A-12C of astud12.
• As shown inFIGS. 2 and 5 theslot27 andstuds12 have a width W′ that is less than the width W of thefoam block11 so the width W′ dimension of thestud12 is disposed within theblock11 so that side surfaces at theside flanges12B of thestud12 are not exposed. For purposes of describing an embodiment of the invention, thewall panel10 may include ablock11 that is 8″ thick, 48″ inches long and 8′ feet high. However, these dimensions are provided by way of example and other dimensions may work for the intended purpose of the subject invention. For typical building specifications for example for a home, thestuds12 may be six inches wide so the side surfaces at theside flanges12B of thestud12 are not exposed as described above. As indicated above theblock11 may be composed of expanded polystyrene foam that is available at a number of different manufacturers or distributors throughout the United States. For example, construction grade expanded polystyrene is manufactured by Insulfoam headquartered in Tacoma, Wash.
• As shown inFIGS. 2 and 5, a mid-point of theslot27A may be slightly offset relative to a lateral center line of theblock11 extending from side end34A to side end34B. In this manner theblock11 may be thicker on one side (15A) of thestud12 than on the other side. Thethicker side15A ofpanel10 may face an exterior of a building to be constructed.Panels10 that are constructed for interior walls or frame members may not require the offset. For thatmatter panels10 that may have a surface facing an exterior of a building do not require the thicker dimension; however, in a preferred embodiment the thicker dimension faces an exterior of a building.
• With respect toFIGS. 5,6 and7, there is shown that twolateral channels28 are cut into thetop end17A andbottom end17B of theblock11 for receivingtracks13A and13B respectively. Thechannels28 are spaced apart and parallel to one another, and contiguous withslots27B as shown inFIG. 5. By cutting thechannels28 there is formed anelongated insert29 between thechannels28 at thebottom end17A andtop end17A of thewall panel10. In addition, about a ¼″ of the surface of theinsert29 is removed forming a recess or notch16 in which thewebs18 of thetracks13A and13B are seated so18 web is substantially flush with top and bottom ends17B and17A.Flanges19 on thetracks13A and13B are seated in thechannels28. In addition, by cuttingchannels28 in theends17A and17B of theblock11 there is formedtop flanges33B andbottom flanges33A on theblock11 that cover sides of thestuds12 andtracks13A and13B atrespective ends17A and17B of thewall panel10.
• After theslots27,channels28 and recesses16 are cut into theblock11, thestuds12 are inserted into theslots12.Wall panels10 thus assembled may be prepared for shipping to a construction site. As noted thepanel10 is secured to or includes abottom track13A that is anchored to aconcrete slab14 as shown inFIGS. 1 and 3. Thepanel10 is lifted andflanges19 ontrack13A are aligned withchannels28 in theblock11 so theelongated insert29 and bottom end of thestuds12 are inserted into thetrack13A. In order to secure thepanel10 to thebottom track13A, theblock11 is adjusted or slid up on thestuds12 so theflanges19 on thebottom track13A are exposed to secure the bottom of thestuds12 to thetrack13A using fastening mechanisms known to those skilled in the art. An adhesive may also applied to the surfaces of thetrack13A,track flanges19 and/orslab14, and theblock11 is then adjusted downward on thestuds13A so thebottom flanges33A on theblock11 abut surfaces of thetrack flanges19,track13A andslab14. The adhesive helps secure theblock11 in place on thepanel10 orslab14 and seals an interface between theflanges33A,track13A andslab14. An adhesive that may be used includes QB4500, which can be purchased at any one of a number of home repair or home supply stores such as Home Depot® and Lowes®.
• Thetop track13B is then secured to a top end of thepanel10 andstuds12. As shown inFIG. 7, theflanges19 on thetop track13B are inserted in thechannels28 on atop end17B on thewall panel10, so theinsert29 and top ends of thestuds12 are inserted in thetrack13B. Fasteners are then driven through thefoam block11,flanges19 on the top track13 and the top ends of thestuds12. The length of thetop tracks13A or bottom tracks may vary from the length of the panel10 (or shorter) or longer to connect together more than onepanel10. At the junction of twotop tracks13A a strap or fastener is provided to secure together thetracks13A.
• In an embodiment, and as shown inFIGS. 1 and 2, awall panel10 has a plurality ofstuds12 embedded in thefoam block11 so thatstuds12 are spaced inward of side ends34A and34B of theblock11 formingfoam block extensions35A and35B at each side end34A and34B of thepanel10. By way of example, apanel10 may be forty-eight inches wide including threestuds12 imbedded in theblock11 and spaced sixteen inches apart, with astud12 spaced about eight inches from each respective side end34A and34B of theblock11.
• With respect toFIG. 8, there is illustrated a top exploded view of the junction of twopanels10.Notches37 are formed in theextensions35A and35B preferably during the hotwire cutting process. Whenpanels10 are aligned end to end on atrack13A,notches37 are also aligned formingvolume37A between thepanels10. Aninsert38 is then inserted in thevolume37A defined by thenotches37 to aid in securing side byside panels10 together. An adhesive, such as the above-referenced QB4500, is preferably applied to theends34A and35B, including at thenotches37, ofpanel10 before theinsert38 is positioned in thevolume37. Whileadjacent notches37 and inserts38 of the embodiment shown inFIG. 8 have a cross-sectional rectangular/square configuration, the invention is not limited to this geometric configuration, and other known configurations may be used. Thefoam column38 preferably has the same geometric configuration as thevolume37 so surfaces of thefoam block11 andcolumn38 abut one another and application of an appropriate adhesive aids is securing panels together. Thefoam insert38 preferably has the same geometric configuration as thevolume37 so surfaces of thefoam block11 andcolumn38 abut one another and application of an appropriate adhesive aids is securing panels together.
• With respect toFIGS. 9,10 and11 there is illustrated ashear wall assembly36 having ends34′A and34′B to which anend34A or34B of aninsulated wall panel10 may be secured. Theshear wall assembly36 includes afoam block11′ that has been cut, as described above, to includeslots27 for receiving or insertingstuds12. In addition, the side ends34′A and34′B have been cut to form a recess41 (seeFIG. 11) to receive thedouble stud assembly40 at the respective ends34′A and34′B of theblock11′. As shown inFIGS. 10 and 12, thedouble stud assembly40 has a generally I-shaped configuration and includes aweb40A and twoflanges40B that are parallel and spaced apart relative to one another and perpendicular theweb40A. In addition each end of the flange may include areturn40C (totally four returns in this example. The double stud assembly may include two studs that abut one another at their respective webs A and are affixed to one another using fasteners such as bolts or rivets, for example. Alternatively, thestud assembly40 may be fabricated as a single structural frame member including the components of two web-to-web abutting studs.
• InFIGS. 11 and 12 there is shown ablock11′ having been cut to receivestuds12.Slots42B and42C are cut into the ends34′A and34′B of theblock11′ to receiverespective flanges40B and returns40C of thestud assembly40. In addition, achannel41 is formed along the height H of theblock11′ at each end34′A and34′B to receive theweb40A and remainder of thedouble stud assembly40 so that returns40C are substantially is flush with the respective ends34′A and34′B of theblock11′.
• In addition, as shown inFIGS. 11 and 12diagonal channels43 are preferably cut into both sides15′A and15′B of theblock11′ for receiving straps44. As shown, thechannels43 extend diagonally across the face ofshear wall assembly36 from a top end of one of thedouble stud assemblies40 positioned at a top corner of theassembly36 to a bottom end of the otherdouble stud assembly40 positioned at a bottom corner of theassembly36. Once thedouble stud assemblies40 are in place, thestraps44 are inserted into thechannels43 and affixed to thedouble stud assemblies40. The strips of foam that have been removed for placement of thestraps44 may be placed over thestraps44 to cover the straps. Adhesive may be used to secure these strips in place. As assembled, theshear wall assembly36 is ready for shipment to a construction site.
• For both theinsulated wall panel10 and the insulatedshear wall assembly36 after the panels are assembled the panel surfaces may be finished to include a cementious or stucco, or other type of wall surface finishing. Typically, a nylon wall mesh may be affixed to the wall surfaces to support a selected wall finishing, so the panels are ready for shipment to a construction site.
• In reference toFIG. 13, there is shown acorner assembly45 that includes twoshear wall assemblies36 affixed to theslab14 and to one another. Thecorner assembly45 includes the ends (34′A or34′B) of theshear wall assemblies36 forming a corner of a building, and acorner stud47 that is bolted to one of thestud assemblies40 of ashear wall assembly36. Abracket46 is anchored to theslab14 and also bolted to each of thedouble stud assemblies40 of theshear wall assemblies36.
• As shown inFIGS. 14A and 14B thebracket46 includes abase plate51 having one ormore apertures51A to secure thebracket46 to theslab14. In addition, thebracket46 includes twovertical plates49A and49B that are disposed perpendicular to one another, and each have one or more apertures to affix thebracket46 in abutting relationship to each ofshear wall assemblies36 at the respectivedouble stud assemblies40. More specifically, thevertical plates49A and49B are secured to therespective webs40A of therespective studs40. The volume between thecorner stud47 and theshear wall assemblies36 is filled with a foam column that is inserted at the corner formed at the junction of the twoshear wall assemblies36.
• In addition,brackets48 are used to anchor thedouble stud assemblies40 of theshear wall assemblies36 distal thecorner assembly45. As shown inFIGS. 15A and 15B, thebracket48 is L shaped having one single vertical plate52 secured to theweb40A of thestud assembly40, and abase plate50 that is anchored to the slab. When apanel10, as shown inFIG. 1, is to be secured on theslab14 and abutting ashear wall assembly36, a foam insert is positioned in thestud40″, ofstud assembly40, facing thepanel10. An adhesive, such as the above-referenced QB4500 is applied to any exposed surface of the foam insert orstud assembly40 and preferably to anend34A or34B of thepanel10. Theend34A and34B of thepanel10 is positioned in abutting contact with theshear wall assembly36 to secure thepanel10 to theshear wall assembly36 and to theslab14. In this manner, apanel10 is secured to theshear wall assembly36. In addition, thepanels10 are secured together as described above forming an exterior and an interior framework for a building.
• With respect toFIG. 16, twoshear panel assemblies36 have been assembled and are positioned relative to one another to form a corner as shown in the drawing. Thebracket46 may be orientated and secured to thestud assemblies40 as shown. During assembly, the bottom sections of thefoam panel11 at the corner may be cut away or removed to positioned and secure thebracket46 to the stud assemblies.
• While the preferred embodiments of the present invention have been shown and described herein, it will be obvious that such embodiments are provided by way of example only. Numerous variations, changes and substitutions will occur to those of skill in the art without departing from the invention herein. Therefore, it is intended that the invention not be limited to the particular disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.

Claims (26)

1. An insulated wall panel, comprising:

a polystyrene foam block having first and second parallel surfaces, top and bottom parallel ends and two parallel side ends, wherein the block is configured to include slots to receive a plurality of studs, and each stud having a generally C-shaped configuration including a web and flanges perpendicular to the web and parallel to one another and the flanges having side surfaces, wherein the studs are spaced apart and in parallel relation to one another within the block between the first and second surfaces and the two side ends of the block so that side surfaces of the flanges on the studs and the webs on the studs are not exposed.

2. The insulated wall panel ofclaim 1, further comprising a first track member having been secured to a building foundation and the first track member having a web member secured to the foundation and two vertically disposed, spaced apart and parallel flanges, and the bottom end of the foam block has two parallel channels formed therein to receive the flanges of the first track and the flanges of the first track are secured to a bottom end of the studs.

3. The insulated wall panel ofclaim 2, wherein the slots formed in the block include a first slot that is contiguous with two second slots that are spaced apart and parallel to one another and perpendicular to the first slot to receive the web member and the flanges of the stud.

4. The insulated wall panel ofclaim 3, wherein the channels formed in the bottom end of the block are contiguous with the second slots that receive the flanges on the studs.

5. The insulated wall panel ofclaim 3, further comprising a second track member secured to a top end of the studs and the second track member having a web member and two vertically disposed, spaced apart and parallel flanges wherein the top end of the foam block has two parallel channels formed therein to receive the flanges of the second track, and the flanges of the second track member are secured to a top end of the studs.

6. The insulated wall panel ofclaim 5, wherein the channels formed in the top end of the block are contiguous with the second slots that receive the flanges on the studs.

7. The insulated wall panel ofclaim 2, further comprising an elongated recess formed in the bottom end of the block between the channels and the web member of the first track member is seated in the recess and the flanges of the first track member are seated in the channels, and the block having flanges adjacent the channels covering the flanges of the first track member.

8. The insulated wall panel ofclaim 5, further comprising an elongated recess formed in the top end of the block between the channels and the web member of the second track member is seated in the recess and the flanges of the second track member are seated in the channels, and the block having flanges adjacent the channels covering the flanges of the second track member.

9. The insulated wall panel ofclaim 1, wherein the panel includes two double stud assemblies and each stud assembly is disposed at a respective side end of the foam block, and there being a plurality of studs disposed within the block and between the double stud assemblies, wherein each double stud assembly includes two studs abutting one another at webs of the studs and are secured to another, wherein each side end of the block having been cut to include a recess extending the height of the respective side end and to include two slots contiguous with the recess, perpendicular to the recess and parallel to one another, wherein a web of the double stud assembly is seated in the recess and flanges of the double stud assembly are seated in the slots.

10. The insulated wall panel ofclaim 9, wherein two such insulated wall panels are secured to a foundation perpendicular to one another forming a corner of a building frame and the double stud assembly for each wall panel and the respective web members thereof are disposed perpendicular to one another and a bracket, having been secured to the foundation, includes a base plate secured to the foundation and two vertically disposed plates perpendicular to one another extending upward from the base plate, and wherein each vertically disposed plate is secured to a web of a respective double stud assembly.

11. The insulated wall panel ofclaim 9, wherein the block is further configured to include two diagonal channels formed in the first and second surfaces of the block, and each of channels extending from a top end of one double stud assembly to a bottom end of the other double stud assembly and intersecting therebetween, the channels being formed for receiving straps that are secured to the respective top and bottom ends of the double stud assemblies.

12. The insulated wall panel ofclaim 1, wherein the studs are offset relative to a lateral centerline of the block, and the block having a thickness dimension on one side of the studs that is greater than a thickness dimension on the other side of the studs, wherein the thicker side of the block is disposed on an exterior side of a building.

13. The insulated wall panel ofclaim 1, wherein studs are spaced inward of each side end of the block forming an extension of the block at each side end thereof wherein a notch is formed in an extension of the block and the notch extends from the bottom end to the top end of the block so that when two wall panels having notches therein are positioned side end to side end a volume is formed between the notches and an insert, having a configuration corresponding to a configuration of the volume, is inserted in the volume to connect the panels.

14. An insulated wall panel, comprising:

a polystyrene foam block having first and second parallel surfaces, top and bottom parallel ends and two parallel side ends, wherein the block is configured to include slots to receive a plurality of studs spaced apart and in parallel relation to one another within the block between the first and second surfaces and the two side ends;

a first track member having a web member secured to a building foundation and two spaced apart vertically disposed flanges that are secured to bottom ends of the studs and the block having channels formed in the bottom end thereof spaced apart and parallel to one another in which the flanges of the first track member are inserted, and an elongated recess formed in the bottom of the block between the channels and extending from one side end to the other side end, and the web of the first track member is positioned in the elongated recess, and the block having parallel flanges at the bottom end thereof on either side of the recess that cover the flanges of the first track member; and,

a second track member having a web member and two spaced apart vertically disposed flanges and the block having channels formed in the top end thereof spaced apart and parallel to one another in which the flanges of the second track member are inserted and secured to top ends of the studs, and an elongated recess formed in the top of the block between the channels and extending from one side end to the other side end of the block and the web of the first track member is positioned in the elongated recess, and the block having parallel flanges at the top end thereof on either side of the recess that cover the flanges of the second track member.

15. The insulated wall panel ofclaim 14, wherein each stud has a generally C-shaped configuration including a web member and two spaced apart parallel flanges attached to the web member and perpendicular thereto, and wherein the slots formed in the block extend from the top end to the bottom end of the block and include a first slot in which the web of the stud is inserted and the first slot is contiguous with two second slots that are spaced apart and parallel to one another and perpendicular to the first slot and in which the flanges of the stud are inserted, and wherein the channels on the bottom end and top end of the block are contiguous with the second slots.

16. The insulated wall panel ofclaim 14, wherein the panel includes two double stud assemblies and each stud assembly is disposed at a respective side end of the foam block, and there being a plurality of studs disposed within the block and between the double stud assemblies, wherein each double stud assembly includes two studs abutting one another at webs of the studs and are secured to another, and the block is further configured to include two diagonal channels formed in the first and second surfaces of the block, and each of channels extending from a top end of one double stud assembly to a bottom end of the other double stud assembly and intersecting therebetween, the channels being formed for receiving straps that are secured to the respective top and bottom ends of the double stud assemblies.

17. The insulated wall panel ofclaim 14, wherein the studs are offset relative to a lateral centerline of the block, and the block having a thickness dimension on one side of the studs that is greater than a thickness dimension on the other side of the studs, wherein the thicker side of the block is disposed on an exterior side of a building.

18. A method of assembling and installing an insulated wall panel, comprising:

providing a polystyrene foam block having first and second parallel surfaces, top and bottom parallel ends and two parallel side ends;

cutting a series of spaced apart slots into the block between the side ends of the block and parallel to one another, and the slots extend from the bottom end of the block to the top end of the block and wherein each slot includes a first slot is parallel to the side ends of the block and two second slots that are contiguous with the first slot and the second slots are parallel to one another and perpendicular to the first slot and within the parallel surfaces of the block;

cutting into the bottom end of the block a first pair of channels that are spaced apart and parallel to one another and extend from one side end to the other side end of the block, wherein the first pair of channels are contiguous with the second slots;

cutting into the top end of the block a second pair channels that are spaced apart and parallel to one another and extend from one side end to the other side end of the block, wherein the second pair of channels are contiguous with the second slots;

cutting into the bottom end of the block an elongated first recess between the first pair of channels, wherein the first recess extends from one side end of the block to the other side end of the block;

cutting into the top end of the block an elongated second recess between the second pair of channels, wherein the second recess extends from one side end of the block to the other side end of the block; and,

inserting a stud into each of the slots of the series of slots wherein each stud has a generally C-shaped configuration including a web member and two flanges parallel to one another and perpendicular to the web member, wherein the web member of a stud is inserted in the first slot and the flanges of a stud are inserted into the second slots.

19. The method ofclaim 18, further comprising:

securing a first track member to a building foundation wherein the track member includes a web member that is secured to the building foundation and two spaced apart parallel flanges that are perpendicular to the web member of the track member;

positioning the block, with studs having been inserted therein, on the first track member with the flanges of the track member being inserted in the first pair of channels and the web of the first track member seated on the first recess;

positioning a second track member, having a web member and two spaced apart parallel flanges that are perpendicular to the web member of the second track member, on the top end of the block with the flanges of the second track member being inserted in the second pair of channels and the web member of the second track member is seated in the second recess;

securing the flanges of the first track member to bottom ends of the studs; and,

securing the flanges of the second track member to top ends of the studs.

20. The method ofclaim 19, further comprising:

cutting a first pair of channels into the first surface of the block wherein the first pair channels are diagonally disposed on the surface and intersect;

cutting a second pair of channels into the second surface of the block wherein the second pair of channels are diagonally disposed on the surface and intersect;

inserting a strap into each channel on the first surface and each channel on the second surface; and,

securing each strap to a top end of a stud and/or a flange of the second track member and to a bottom end of a stud and/or a flange of the first track member.

20. The method ofclaim 19, further comprising:

cutting a notch into a side end of the foam block for a first wall panel wherein the notch extends from the bottom end of the block to the top end of the block;

cutting a notch into a side end of a foam block for a second wall panel wherein the notch extends from the bottom end of the block to the top end of the block;

positioning the first wall panel adjacent to the second wall panel wherein notches on the respective wall panel face each other forming a volume therebetween; and,

inserting a polystyrene foam insert into the volume to connect together the first and second wall panels.

22. The method of claim21, further comprising applying an adhesive to the surface of each end of the block for the respective first and second wall panels at the notches and/or applying the adhesive to the insert.

23. An insulated wall panel system, comprising:

a plurality of polystyrene foam blocks each having first and second parallel surfaces, top and bottom parallel ends and two parallel side ends, wherein each block is configured to include slots to receive a plurality of studs spaced apart and in parallel relation to one another within the block between the first and second surfaces and the two side ends and the blocks are aligned side end to side end;

a plurality of first track members each having a web member secured to a building foundation and two spaced apart vertically disposed flanges that are secured to bottom ends of the studs and the blocks having channels formed in the bottom end thereof spaced apart and parallel to one another in which the flanges of the first track members are inserted, and an elongated recess formed in the bottom of each block between the channels and extending from one side end to the other side end, and each web of the first track member is positioned in the elongated recess, and the blocks having parallel flanges at the bottom end thereof on either side of the recesses that cover the flanges of the first track members; and,

a plurality of second track members each having a web member and two spaced apart vertically disposed flanges and the blocks having channels formed in the top ends thereof spaced apart and parallel to one another in which the flanges of the second track members are inserted and secured to top ends of the studs, and an elongated recess formed in the top of each block between the channels and extending from one side end to the other side end of each block and the web of each first track member is positioned in the elongated recess, and each block having parallel flanges at the top ends thereof on either side of the recesses that cover the flanges of the second track members.

24. The insulated wall panel system ofclaim 23, studs for each wall panel are spaced inward of each side end of a respective block forming an extension on the blocks at each side end thereof wherein a notch is formed in an extension of each respective block and the notch extends from the bottom end to the top end of each block so that when two wall panels having notches therein are positioned side end to side end a volume is formed between the notches and an insert, having a configuration corresponding to a configuration of the volume, is inserted in the volume to connect the panels.

25. The insulated wall panel system ofclaim 23, further comprising two corner wall panels that each includes two double stud assemblies and each stud assembly is disposed at a respective side ends of each of the foam blocks of the wall panels, and there being a plurality of studs disposed within each block and between the double stud assemblies, wherein each double stud assembly includes has a generally I-shaped configuration with a web and two spaced apart flanges that are parallel to one another and perpendicular to the web, wherein each side end of each block for a respective corner wall panel having been cut to include a recess extending the height of the respective side end and to include two slots contiguous with the recess, perpendicular to the recess and parallel to one another, wherein a web of the double stud assembly is seated in the recess and flanges of the double stud assembly are seated in the slots.

26. The insulated wall panel system ofclaim 24, wherein the two corner panels are secured to a foundation perpendicular to one another forming a corner of a building frame and the double stud assembly for each wall panel and the respective web members thereof are disposed perpendicular to one another and a bracket, having been secured to the foundation, includes a base plate secured to the foundation and two vertically disposed plates perpendicular to one another extending upward from the base plate, and wherein each vertically disposed plate is secured to a web of a respective double stud assembly.

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