Finishes”

Field of the Invention

The present invention pertains to building renovation systems, specifically panelized interior

retrofits that upgrade both thermal performance and utility infrastructure (mechanical, electrical,

and plumbing) without requiring demolition of existing walls.

Background and Prior Art

Buildings constructed prior to the mid-20th century often have inadequate insulation, outdated

wiring or plumbing, and substantial irregularities in their walls due to settling or original

craftsmanship. Traditional renovation approaches require stripping old walls down to the studs,

installing new insulation, and re-running in-wall utilities, resulting in high labor costs, extensive

2. Dricore® SMARTWALL uses an insulation panel pre-bonded to drywall with standardized

wire channels. Although this reduces finishing steps, it remains limited to typical

electrical conduit or cables, and excludes deeper channels for plumbing or thicker

furring, and often fails to provide continuous insulation.

Problems with Existing Solutions

● Lack of a Comprehensive Retro System: Most prior art focuses on either standard,

minimal-depth wire channels or standardizing new in-wall wiring.

● Limited Fire Rating: Some insulation panels necessitate a separate drywall or gypsum

layer.

● Incompatibility with Varied MEP: Larger plumbing lines or small duct lines (e.g., mini-split

Summary of the Invention

This invention provides an interior retrofit system that:

1. Retains Existing Walls: No demolition needed—MEP lines (plumbing, wiring, low-voltage,

mini-split lines) are first mounted on top of the old wall.

2. Custom or Semi-Custom CNC Routing: Foam insulation panels (e.g., EPS or polyiso) are

routed on the back side to accommodate surface-mounted MEP. Channels can be sized

4. Adaptive Fit Over Irregular Walls: The foam layer can be varied in thickness or channel

depth to nest over surface-mounted lines. Optional scanning or measurement techniques

further enhance accuracy, reducing field rework.

5. Minimal-Disruption Installation: The panel is adhered or anchored directly to the old

wall, concealing MEP within milled foam channels. Seams are taped/finished similar to

drywall, creating a continuous thermal and interior finish layer.

Novelty and Distinguishing Features

While prefabricated insulation panels and routing for wiring are known, the invention

distinguishes itself by:

from the moment panels are installed.

3. Surface-Mounted MEP, then Overlay: Traditional retrofits place MEP inside new studs or

track systems. Here, MEP is intentionally run on the existing substrate first, tested, and

visually inspected, then “captured” by the backside foam channels. This sequence

ensures no demolition of existing plaster or masonry and dramatically cuts labor.

4. Optional Digital Layout for Precision: Using room scanning or laser measurement to

generate CNC toolpaths for routing channels exactly where existing lines lie. This is

5. Scalable Minimal-Demo Retrofit: The synergy of continuous insulation, fully integrated

by any single prior system at scale.

Brief Description of the Drawings

1. Figure 1 (Panel Architecture): Exploded view showing MgO skin, foam core, and

channels.

2. Figure 2 (Wall Cross-Section): How the panel back encloses surface-mounted conduit or

pipes.

3. Figure 3 (Before-and-After Frontal View): Old wall with bracketed MEP vs. the new panel

○ (a) Cap or remove defunct lines, attach new MEP lines on the wall.

○ (b) Optionally scan or measure the finished MEP layout.

○ (e) Adhere or screw the finished panels to the wall.

3. Finishing: Joints between panels are taped or sealed; standard interior paint or finish

coats are applied as desired.

4. Performance: Achieves building code compliance via Class A interior finish, improved

R-value, and accessible MEP that is tested prior to coverage.

Potential Variations

● Standardized Panels: Without scanning, standard channel patterns can be used (vertical

channels every 16” plus horizontal runs for typical outlet heights).

● Removable Panel Sections: Optionally incorporate removable access panels or hinged

Claims (Simplified)

1. A panel system for interior retrofit comprising a foam insulation core with custom or

standardized channels sized for MEP lines, a fire-rated MgO facing adhered to the core,

on an existing wall.

2. A method of retrofitting an existing building interior by:

(b) scanning or measuring MEP positions,

channels for deeper plumbing lines, minimizing field modifications.