Building system

Abstract

A building wall structure having increased heat insulating qualities. The building wall structure comprises a plurality of foam panels that are arranged substantially around the exterior of the building frame. The plurality of foam panels collectively define an insulative barrier. The insulative barrier is also designed such that exterior cladding such as stucco, siding, or the like can be attached to the insulative barrier. Moreover, the attachment hardware used to attach the foam panels to the frame and the cladding to the foam panels are substantially isolated thermally to thereby inhibit heat transfer between the interior and exterior of the building.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] (Not Applicable)

STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT

[0002] (Not Applicable)

BACKGROUND OF THE INVENTION

[0003] The present invention relates in general to a building system, and in particular to a building wall and/or roof structure insulation system employing foam panels and fastening members that are substantially isolated therein, and to which cladding can be attached, thereby providing improved heat transfer characteristics at reduced costs.

[0004] It is generally recognized that construction in general, and residential construction in particular, often suffers from poor building materials and/or poor construction practices. As a result, the amount of heat transfer that occurs in an average building over the course of high-temperature and low-temperature seasons has resulted in increased heating and cooling costs. While heat transfer can occur through roof structures, windows, doors, chimneys, and the like, a major contributor toward heat transfer occurs through typical wall structures. In particular, many such wall structures are little more than support posts or studs, insulation material positioned between the studs, an inside sheet of thin drywall, and an outside finish material applied over a mesh base. As such, a large degree of heat transfer can occur through the studs, especially when the wall comprises metallic studs. As a result, temperature changes on the outside of the building can quickly cause unfavorable temperature changes within the building. Thus, the occupants are more likely to become uncomfortable due to the unfavorable temperatures, or the costs of heating and cooling the building is likely to increase in order to counteract the temperature changes.

[0005] Various attempts have been made to address these concerns. For instance, some prior art teachings comprise expanded polystyrene and/or urethane rigid foam sheets that are positioned in and around the studs such that the heat transfer path from the building interior, through the stud, and the building exterior is largely impeded by the foam.

[0006] However, thermally conductive (i.e., metallic) fasteners typically are used to affix the foam sheets to the studs. As such, thermal energy is able to transfer through the fasteners because they are affixed directly to the stud and are largely exposed to the exterior ambient temperature.

[0007] Additionally, the foam sheets are typically ill-suited for bearing structural loads. Thus, stucco and other sidings for the exterior of the building usually cannot be directly affixed to the foam sheets, or else the foam sheets would likely collapse under the weight of the siding. Extra long fasteners are therefore often used to affix the siding, with the fasteners extending through the cladding foam and into the stud. Disadvantageously, the extra long fasteners are more expensive to purchase and install than standard length fasteners. Additionally, heat transfer occurs through the fasteners because they are affixed directly to the stud, extend through the foam insulation, and are additionally exposed to the exterior ambient temperature.

[0008] Finally, foam sheeting can be costly, especially considering the large amount of sheeting that is used to cover an entire building structure. It is understood that thicker foam results in increased insulating capability; however, as the foam thickness increases, foam material costs substantially increase. As such, there exists a trade off between insulating capability and cost concerns with foam insulation.

[0009] Thus, a need yet remains for a rigid foam insulation wall and/or roof structure that substantially inhibits paths of heat transfer, especially through the studs and fasteners. Also, a need remains for an insulating wall structure that is capable of supporting siding or stucco in a manner that allows standard length fasteners to be used and in a manner that inhibits fasteners from acting as heat transfer paths. Finally, a need yet remains for an insulating wall structure that reduces costs associated with such a rigid foam insulation system.

BRIEF SUMMARY OF THE INVENTION

[0010] These needs as well as other needs associated in the prior art are addressed below in the disclosure of a building wall and/or roof structure insulation system comprising a plurality of parallel, intermittently-spaced frame members (e.g., studs and rafters). The frame members each include an outer side and an inner side. The plurality of outer sides collectively defines an exterior side of the building wall frame.

[0011] The building wall structure further comprises an insulative barrier made up of rigid polyethylene and/or polyurethane insulative panels. Each insulative panel includes an inner side that is positioned adjacent to the exterior side of the frame and an outer side separated from the inner side by a first thickness. The plurality of insulative panels collectively defines an exterior side of the insulative barrier.

[0012] Also, the building wall structure includes a plurality attachment members, each including a first portion and a second portion. The first portion is positioned adjacent to the inner side of the respective insulative panel. The second portion partially lies within the first thickness of the respective insulative panel.

[0013] Moreover, the building wall structure has cladding positioned adjacent to the outer side of the insulative barrier. The cladding is attached to the insulative barrier with a plurality of second fasteners that extend through a portion of the first thickness.

[0014] As such, the building wall structure thermally isolates the fasteners used to attach the insulative panels to the frame and the fasteners used to attach the cladding to the insulative barrier. Thus, the fasteners significantly reduce heat transfer between the inside and outside of the building wall structure. As a result, the temperature inside the building is less likely to be affected by temperature changes outside. Thus, occupants of the building are more likely to be comfortable and the associated heating and cooling costs are likely to decrease. Furthermore, the building wall structure advantageously reduces costs because optimally-sized insulative panels can be utilized in a cost effective manner. These and other objects of the present invention will become apparent throughout the description thereof which now follows.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] These as well as other features of the present invention will become more apparent upon reference to the drawings wherein:

[0016] FIG. 1 comprises an overhead perspective view of a building formed utilizing the insulative wall/roof structure insulation system of the present invention;

[0017] FIG. 2 is a cross sectional view of the wall structure of FIG. 1 taken along the line 1-1 of FIG. 1;

[0018] FIG. 3 is a top perspective view of a purlin suitable for use in the wall structure of FIG. 1;

[0019] FIG. 4 is a cross sectional view of the wall structure of FIG. 1 taken along the line 2-2 of FIG. 1;

[0020] FIG. 5 is a top perspective view of an eave bracket suitable for use in the novel wall structure of FIG. 1; and

[0021] FIG. 6 is a cross sectional view of an alternative embodiment of the wall structure of FIG. 1 taken along the line 6-6 of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

[0022] Referring now to the drawings wherein the showings are for purposes of illustrating preferred embodiments of the present invention only, and not for purposes of limiting the same, FIG. 1 depicts a building structure 100. As shown, an exterior rigid insulative barrier 112 is attached to the building structure 100 in a manner to be described in greater detail below. In the preferred embodiment, the insulative barrier 112 generally includes a plurality of base brackets 160, drip edges 170, rigid foam panels 114, purlin 116, eave brackets 142, and bats 134. The insulative barrier 112 inhibits heat transfer between the inside and outside of the building structure 100 to thereby keep the air temperature inside more constant and consequently lower heating and cooling costs.

[0023] As stated, the insulative barrier 112 includes a plurality of rigid expanded foam panels 114 formed from expanded polystyrene or urethane. The foam panels 114 are abutted and attached together and to the building structure 100 in a manner that will be explored in greater detail below. As will be recognized, the foam panels 114 inhibit heat transfer between the interior and exterior of the building structure 100.

[0024] In one embodiment, the foam panels 114 are provided with a radiant barrier 140, comprising a thin sheet of material capable of inhibiting radiative heat transfer, such as aluminum. As shown in FIG. 2, the radiant barrier 140 is affixed to one side (e.g., the interior side) of the first foam panel 124. Preferably, the radiant barrier 140 is attached to the foam panels 114 before they are attached to the building structure 100 because the fragile radiant barrier 140 has less tendency to tear. As such, the radiant barrier 140 enhances energy efficiency, and blocks 97% of summer radiant heat from entering the building structure 100 and helps to retain heat within the building structure 100 during cold weather.

[0025] In another embodiment, the radiant barrier 140 is formed from a plastic film with aluminum coating. As such, the added plastic of the radiant barrier 140 acts as a barrier to air and moisture from entering the building structure 100.

[0026] Moreover, as stated, the insulative barrier 112 includes a plurality of base brackets 160, shown in FIGS. 1 and 2. In the embodiment shown, the base bracket 160 comprises an elongate channel having a U-shaped cross section and is preferably fabricated from light gauge bent sheet metal. As such, the base bracket 160 includes a base 164 and an interior flange 162 and an exterior flange 166 that both extend vertically upward from opposing sides of the base 164. As will be described in greater detail below, the base bracket 160 provides attachment means for the lower portion of the foam panels 114 to the building structure 100. Furthermore, the base bracket 160 acts as a shield against insects and rodents from burrowing into the foam panels 112.

[0027] Furthermore, the insulative barrier includes a plurality of drip edges 170, shown in FIGS. 1 and 2. In the preferred embodiment, the typical drip edge 170 comprises an elongated piece of light gauge bent sheet metal that defines a base 174. The drip edge 170 further defines an interior flange 172, which extends downwardly at an angle from the base 174. Also, the drip edge 170 defines an exterior flange 176, which extends upwardly at approximately a ninety degree angle from the base 174. The drip edges 170 are attached to the base brackets 160 and the lower portion of the foam panels 114 in a manner to be described in greater detail below. Positioned as such, the drip edges 170 divert rainwater away from the building structure 100 and insulative barrier 112, thereby inhibiting corrosion. Also, the drip edges 170 act as a shield against insects and rodents from burrowing into the foam panels 112. Finally, the drip edges 170 provide attachment means for cladding to be attached to the insulative barrier 112 as will be described in greater detail below.

[0028] As stated above, the insulative barrier 112 includes a plurality of purlin 116, shown in FIGS. 1-4. As best shown in FIG. 3, the purlin 116 comprises an elongate, bent member having a Z-shaped cross section, and made out of bent sheet metal in one embodiment. As such, the purlin 116 includes a base 192, and an interior flange 190 and a support flange 194 that both extend outward in different directions from opposing sides of the base 192. A plurality of openings 191 are formed in the interior flange 190, and fasteners fit through these openings 191 for attaching the purlin 116 to the building structure 100 as will be described below. The purlin 116 preferably includes plural dimples 193, which are depressions of the material surrounding the openings 191. Preferably, the dimples 193 are depressed enough such that the head of the screw fasteners that fit through the openings 191 (as described below) are countersunk below the surface of the interior flange 190 of the purlin 116. The purlin 116 also includes plural interconnection flanges 196. In one embodiment, the interconnection flanges 196 are formed by cutting areas of the base 192 adjacent to the support flange 194 and bending the areas so as to be parallel with the support flange 194. Also, in the embodiment shown, the purlin 116 includes a plurality of holes 198 having multiple diameters. In one embodiment, the holes 198 are formed through the base 192 of the purlin. The holes 198 reduce the overall weight and thermal mass of the purlin 116 decreases thermal transfer through the foam panel 114. Thus, as described in greater detail below, the purlin 116 allow the foam panels 114 to abuttingly attach to each other and to attach the foam panels 114 to the building structure 100.

[0029] As stated, the insulative barrier 112 includes a plurality of eave brackets 142, of which an exemplary embodiment is shown in detail in FIG. 5. In one embodiment, the eave bracket 142 comprises a thin elongate member made of bent sheet metal in one embodiment. As such, the eave bracket 142 includes a base 143 and a support flange 144 extending at an angle therefrom. Also, the eave bracket 142 is provided with a plurality of holes 198 having a variety of diameters and extending through the base 143 of the eave bracket 142. The holes 198 reduce the overall weight of the eave bracket 142 and the thermal mass of the eave bracket 142 to thereby enhance the insulative qualities of the insulative barrier 112. As will be described in greater detail below, each eave bracket 142 provides attachment means between foam panels 114 and the roof of the building structure 100.

[0030] Furthermore, the insulative barrier 112 includes a plurality of bats 134, as shown in FIGS. 1 and 4. Each bat 134 is a thin, narrow strip which is made out of metal in one embodiment. As will be described in greater detail below, each bat 134 is positioned on the exterior side of foam panels 114 positioned on the roof of the building structure 100. As such, the bats 134 provide attachment means for roofing materials to attach to the insulative barrier 112 in a thermally efficient manner.

[0031] Thus, FIGS. 1, 2, and 4 illustrate the insulative barrier 112 attached to the building structure 100. The building structure 100 comprises a plurality of studs 102, which are elongate members typically having a rectangular cross section. It should be noted that the studs 102 can be fabricated from a variety of materials including, but not limited, to wood and/or metal. In the preferred embodiment however, the studs comprise 20-gauge metal studs. The studs 102 are laterally spaced and extend upwardly from a U-shaped track 103 affixed to a foundation 104, with the upper ends of each of the studs 102 affixed to a top plate 105. Generally, the studs 102 define a wall 101 of the building structure 100.

[0032] Also, the building structure 100 includes a plurality of rafters 108, typically having a rectangular cross section and formed out of metal and/or wood, like the studs 102. The rafters 108 are supported on the top plate 105 and extend angularly upward to define a roof 107 of the building structure 100.

[0033] Collectively, the studs 102 and the rafters 108 define a building frame 110. The building frame 110 defines a building interior 120, which is the total volume between the walls 101, roof 107, and foundation 104. The building frame 110 also defines an exterior 122, which is the total volume not included within the interior 120.

[0034] As is conventional, the building 100 further includes internal wall covering structure 199 (i.e., drywall). In one embodiment the internal wall covering 199 is attached via drywall screws to the interior 120 sides of the wall studs 102 and rafters 108.

[0035] As stated above, the insulative barrier 112 comprises a plurality of foam panels 114. For purposes of discussion, the foam panels 114 of the insulative barrier 112 are grouped into three types. First, a plurality of first foam panels 124 are included, which are primarily positioned nearest the foundation 104 of the building structure 100. Second, a plurality of second foam panels 126 are included, which are primarily positioned nearest the intersection of the walls 101 and roof 107 of the building structure 100. Third, a plurality of roof foam panels 128 are included, which are primarily positioned atop the roof 107 of the building structure 100. Each of the three types of foam panels 114 includes specific features which aid in attaching the foam panels 114 to the building structure 100.

[0036] Beginning with FIG. 2, a representative first foam panel 124 is shown. The rectangular cross section of the first foam panel 124 defines an interior side 151, an exterior side 152, a top side 153, and a bottom side 154. Each first foam panel 124 includes a first channel 150, which is a vertically oriented slit cut into the bottom side 154 at a predetermined distance between the interior and exterior sides 151, 152. Each first foam panel 124 also includes a second channel 148, which is a vertically oriented slit cut into the top side 153 at a predetermined distance between the interior and exterior sides 151, 152.

[0037] Attachment of the first foam panels 124 begins by positioning the base brackets 160 and the drip edges 170 adjacent the studs 102 and foundation 104. More specifically, these components are positioned such that the interior flange 162 of the base brackets 160 is positioned against respective studs 102 such that the base 164 of each base bracket 160 extends away from the respective studs 102. Also, the drip edges 170 are positioned such that a portion of the base 164 of each base bracket 160 lies over a portion of the respective base 174 of the drip edge 170. Furthermore, the exterior flanges 176 of each drip edge 170 is positioned parallel to the exterior flanges 166 of the respective base bracket 160 but at a distance away therefrom. A plurality of first fasteners 180 is screwed through each interior flange 162 to attach the base brackets 160 to the studs 102.

[0038] Next, the first foam panels 124 are positioned atop the base brackets 160 and drip edges 170 such that the exterior flanges 166 of each base bracket 160 fits within the first channels 150 of the first foam panels 124. Also, and the exterior flanges 176 of each drip edge 170 is positioned adjacent the exterior side 152 of the first foam panel 124. A plurality of second fasteners 182 is screwed through the exterior flanges 176 of the drip edges 170, through the first foam panels 124, and through the exterior flanges 166 of the base brackets 160 to attach the components together.

[0039] Subsequently, a plurality of first fasteners 180 are individually screwed through the openings 191 of the of the purlin the purlin 116 to attach the same to the studs 102. Preferredly, attachment of the purlin 116 allow the support flanges 194 to fit within the second channel 148 of the first foam panel 124. As such, the interconnection flanges 196 of the purlin 116 extend upward, out of the second channels 148.

[0040] In one embodiment, the first foam panels 124 are attached in this manner until the portion of the building structure 100 nearest the foundation 104 is surrounded by first foam panels 124. As shown in FIG. 2, additional first foam panels 124 are abuttingly stacked on top of other first foam panels 124. In order to stack first foam panels 124 in this manner, the upper first foam panel 124 is positioned such that the interconnection flanges 196 of the purlin 116 fits within the first channel 150 of the first foam panel 124 lying immediately above. This stacking continues until the walls 101 are substantially covered by first foam panels 124.

[0041] Then begins attachment of the second foam panels 126, as illustrated in FIG. 4. The second foam panels 126 are similar to the first foam panels 124 except that the top side 153 is cut at an angle relative to the slope of the roof 107. The second foam panels 126 are stacked atop the first foam panels 124 such that the interconnection flanges 196 of the purlin 116 lying below the second foam panels 126 individually fit within the first channels 150 of the second foam panels 126. Furthermore, the eave brackets 142 are attached to the rafters 108 with first fasteners 180 such that each base 143 extends away from their respective rafter 108. The support flanges 144 of the eave brackets 142 fit within the respective second channels 148 of the second foam panels 126.

[0042] In the preferred embodiment, a cladding 130 is included on the building structure 100. The cladding 130 can be generally known materials such as stucco, aluminum siding, and the like. The cladding 130 is attached adjacent to the exterior sides 152 of the first and second foam panels 124, 126. More specifically, in the case of the first foam panels 124 shown in FIGS. 2 and 4, a plurality of second fasteners 182 are screwed through the cladding 130, through the first foam panels 124, and through the support flanges 196 of the purlin 116 to attach the cladding 130. Similarly, in the case of the second foam panels 126 shown in FIG. 4, a plurality of second fasteners 182 are screwed through the cladding 130, through the second foam panels 126, and through the support flanges 144 of the eave brackets 142 to attach the portion of the cladding 130 near the roof 107. As such, the cladding 130 provides an aesthetically pleasing surface for the exterior 122 of the building structure 100.

[0043] Furthermore, installation of the insulative barrier 112 includes attachment of the roof foam panels 128, which is illustrated in FIG. 4. The typical roof foam panel 128 is substantially similar to the first and second foam panels 124, 126 except that the roof foam panel 128 is positioned over the rafters 108. In order to attach the roof foam panels 128, the interior flange 190 of the purlin 116 is attached to the rafter 108 with a first fastener 180 in the manner described above. Then, the support flange 194 of the purlin 116 is positioned within the second channel 148 of the roof foam panel 128 as is shown in FIG. 1. This leaves the interconnection flange 196 of the purlin 116 extending out of the roof foam panel 128. Then, additional roof foam panels 128 are abuttingly positioned such that the interconnection flange 196 is positioned within the first channel 150 of the added roof foam panels 128. Preferably, this process is continued until all rafters 108 are covered by interconnected roof foam panels 128.

[0044] Once the roof foam panels 128 are installed, a plurality of bats 134 are positioned over the junctions between individual roof foam panels 128 as shown in FIG. 1. Then, a plurality of second fasteners 182 are screwed through the bat 134, through the roof foam panels 128, and through the support flanges of the purlin 116. Then, a roofing material 136, such as shingling or other known material, is positioned over the plurality of bats 134 in a known manner.

[0045] Thus, the insulative barrier 112 detailed above provides increased thermal efficiency for typical building structures 100. In one aspect, the foam panels 114 inhibit heat transfer between the interior and exterior of the building structure 100 such that the air temperature inside remains more constant. Consequently heating and cooling costs are likely to be lower. It is understood that this insulative barrier 112 could be installed on both new building structures by installing the same around the newly built frame. However, the insulative barrier 112 could also be installed around an existing building structure simply by removing existing cladding and/or roofing material and then installing the insulative barrier 112 around the remaining portions of the building structure 100.

[0046] Furthermore, although the illustrated embodiment of the insulative barrier 112 is formed around both the walls 101 and roof 107 of the building structure 100 entirely, it is understood that the insulative barrier 112 could be exclusively formed around the walls 101, portions of the walls 101, or the roof 107 only. Thus, the insulative barrier 112 can be conveniently positioned where necessary.

[0047] Moreover, it should be noted that neither the plurality of first or second fasteners 180, 182 span the entire distance between the interior side 151 and exterior side 152 of the foam panels 114. As such, both the first and second fasteners 180, 182 are thermally isolated by the foam panels 124. Such isolation inhibits heat transfer between the interior 120 and the exterior side 152 of the foam panel 114 through the fasteners 180, 182. Advantageously, air temperature changes outside the building 100 are less likely to affect the air temperature inside the building 100.

[0048] Also, it is noted that the purlin 116 and eave brackets 142 include a plurality of holes 198. These holes 198 reduce the thermal mass of the purlin 116 and eave brackets 142 to thereby increase the thermal efficiency of the insulative barrier 112.

[0049] Moreover, as shown in FIGS. 1, 2, and 4, the interior paneling 199 is separated at a distance from the foam panels 114. In other words, the studs 102 and/or the rafters 108 are sandwiched by the interior paneling 199 and the foam panels 114. It is understood that a substantial amount of air would be contained between the interior paneling 199 and the foam panels 114. It is also understood that air has substantial thermal insulation qualities. Thus, the air sandwiched between the interior paneling 199 and the foam panels 114 further inhibits heat transfer between the interior 120 and exterior 122 of the frame 110. In one embodiment, holes are included in the studs 102 only where absolutely necessary (i.e., where wires must pass through studs 102) to minimize convective heat transfer between the studs 102. Advantageously, the insulative barrier 112 further maintains the air inside the building 100 at a more constant temperature, thereby reducing heating and cooling costs.

[0050] Still further, it is noted that the plurality of bats 134 separate the roofing material 136 from the roofing foam panel 128 by a first distance 137. The first distance 137 preferably contains nonmoving air. Because air has advantageous thermal insulation qualities, the first distance 137 further inhibits heat transfer between the interior 120 and exterior 122 of the frame 110. Thus, the air temperature inside the building 100 is more likely to remain constant, and heating and cooling costs are likely to be advantageously lower.

[0051] Additionally, it is noted that the insulative barrier 112 provides an insulative layer over the top of the roof 107 of the building structure 100. This is unlike most prior art applications which insulate only the top horizontal level of the building 100 and leave the attic portion of the building 100 uninsulated. Oftentimes, components and associated piping are positioned within the attic, and the efficiency of those components can be detrimentally affected by temperature changes in the attic. Thus, because the insulative barrier 112 shown in FIG. 4 insulates the attic of the building 100, the components and associated piping stored in the attic are likely to operate more efficiently.

[0052] It is understood that the foam panels 114 could take on a variety of thicknesses, widths, and heights. In one embodiment, the thickness of the individual foam panels 114 equals four inches, the width equals two feet and the height equals six feet. At such dimensions, multiple foam panels 114 can be cut from a single standard foam block. This advantageously reduces costs since specially dimensioned foam panels 114 are likely not necessary, and off-the-shelf foam panels 114 can be obtained instead.

[0053] Turning now to FIG. 6, an alternative embodiment of the insulative barrier 112 is illustrated. As shown, the alternative insulative barrier 112 comprises a first foam panel 124 and a second foam panel 126 that are arranged exterior 122 to the stud 102. However, in this embodiment, the first and second foam panels 124, 126 are thicker than the foam panels 124, 126 in the embodiments described herein above. As will be described below in more detail, the increased thickness of the first and second foam panels 124, 126 advantageously increase the insulating capability of the insulative barrier 112.

[0054] The first foam panel 124 is supported on its bottom side 154 by the base bracket 160 similar to the embodiment described herein above. The bottom side 154 is also supported by the drip edge 170 much like the drip edge 170 described herein above; however, the base 174 of the drip edge 170 is longer due to the increased thickness of the first foam panel 124. More specifically, the base 174 is preferably long enough to allow the exterior flange 176 of the base bracket 170 to contact the exterior side 152 of the first foam panel 124, yet still contact the base 164 of the base bracket 160. Also, a third fastener 184 attaches the exterior flange 176 of the drip edge 170 to the exterior flange 166 of the base bracket 160. Accordingly, the third fastener 184 is able to span the distance between the exterior flanges 166, 176.

[0055] Moreover, the first foam panel 124 further comprises a third channel 156. The third channel 156 is a small slit extending vertically downward from the top side 153 of the first foam panel 124. Inside the third channel 156 lies an expansion strip 157. In one embodiment, the expansion strip 157 comprises a rectangular piece of sheet metal. In the preferred embodiment, the expansion strip 157 is dimensioned such that a portion of the expansion strip 157 extends outward from the third channel 156 when positioned therein.

[0056] Also, as shown in FIG. 6, the second foam panel 126 comprises a fourth channel 158, a vertical slit that extends upward from the bottom side 154 of the second foam panel 126. As shown in FIG. 6, the expansion strip 157 extends out of the third channel 156 in order to substantially fill the fourth channel 158 as well.

[0057] In the embodiment shown in FIG. 6, the cladding 130 is attached to the first and second foam panels 124, 126 with second fasteners 182. More specifically, the second fasteners 182 extend through the cladding 130, through the first or second foam panel 124, 126 and through the expansion strip 157. In the preferred embodiment, the expansion strip 157 is positioned near enough to the cladding 130 so as to allow the second fasteners 182 to be of a less expensive standard length. Moreover, it is noted that the secondary fasteners 182 are attached to the expansion strip 157 and the expansion strip 157 is substantially isolated by insulating foam. Thus, the insulative barrier 112 can advantageously insulate more effectively due to the isolation of the second fasteners 182 and expansion strip 157.

[0058] It is understood that as the foam panels 124, 126 increase in thickness, the insulative barrier 112 becomes more effective at inhibiting heat transfer between the interior 120 and exterior 122 of the frame 110. In the embodiment shown in FIG. 6, the first and second foam panels 124, 126 can be increased to a wide variety of thicknesses. In preferred embodiments, the thickness of the foam panels 124, 126 can take on a variety of thicknesses without having to change the dimensions of the purlin 116, expansion strip 157, or second fasteners 182. This advantageously adds modularity to the insulative barrier 112, thereby allowing different insulative barriers 112 to be used on different buildings 100 without adding additional costs.

[0059] Thus, the embodiment of the insulative barrier 112 shown in FIG. 6 comprises foam panels 124, 126 with increased thickness such that the insulative barrier 112 likely has increased insulating qualities. Thus, the air inside the building 100 is advantageously more likely to remain at a comfortable level with less need for the use of secondary air heaters or coolers.

[0060] In summary, FIG. 1 through FIG. 6 illustrate various embodiments of an entire insulative barrier 112 for a building 100. As noted, the first and second fasteners 180, 182 are substantially isolated by the foam panels 124, 126, 128, meaning that the fasteners 180, 182 are unlikely to act as heat transfer paths between the inside and outside of the building 100. Also, external positioning of the foam panels 124, 126, 128 outside of the frame 110 forms an insulating air pocket between the interior paneling 199 and the foam panels 124, 126, 128. Moreover, holes 198 are formed in the purlin 116 and the eave bracket 142 to further reduce the transfer of thermal energy. Collectively, these separate features give the insulative barrier 112 increased insulating qualities. Advantageously, the air on the interior of the building 100 is more likely to remain at a comfortable level.

[0061] Furthermore, the embodiments shown in FIGS. 1 through 6 reduce costs. First, costs of operating air heaters likely decrease because of the insulative qualities of the insulative barrier 112. Second, the radiant barrier 140 inhibits radiative heat transfer and allow thinner, less expensive foam panels 124, 126, 128 to insulate effectively. Third, one specific embodiment of the insulative barrier 112 disclosed herein allows multiple foam panels 114 to be formed from standard foam blocks, thereby advantageously avoiding the increased cost of obtaining specially-sized foam panels 114. Fourth, as detailed herein above, the same size of purlin 116, eave brackets 142, and second fasteners 182 can be used in conjunction with foam panels 114 of different thicknesses. This feature advantageously allows for modular design of the insulative barrier 112 without incurring the costs of redesigning the purlin 116, eave brackets 142, and second fasteners 182.

[0062] This disclosure provides exemplary embodiments of the present invention. The scope of the present invention is not limited by these exemplary embodiments. Numerous variations, whether explicitly provided for by the specification or implied by the specification, such as variations in structure, dimension, type of material and manufacturing process may be implemented by one of skill in the art in view of this disclosure.

Claims

1. A building wall structure comprising:

a building frame comprising a plurality of frame members, each including an outer side and an inner side, the plurality of outer sides collectively defining an exterior side of the building frame;

an insulative barrier comprising a plurality of insulative panels, each including an inner side that is positioned adjacent to the exterior side of the frame and an outer side separated from the inner side by a first thickness, the plurality of insulative panels collectively defining an exterior side of the insulative barrier;

a plurality of attachment members, each including:

a first portion positioned adjacent to the inner side of the respective insulative panel; and

a second portion that partially lies within the first thickness of the respective insulative panel;

a plurality of first fasteners attaching the plurality of insulative panels to frame members via the first portion of the attachment members such that each first fastener is isolated from the exterior side of the insulative barrier by the first thickness; and

cladding positioned adjacent to the outer side of the insulative barrier and attached to the insulative barrier with a plurality of second fasteners that extend through a portion of the first thickness.

2. The building wall structure of claim 1, wherein at least one insulative panel comprises a film capable of inhibiting radiative heat transfer, wherein the film is attached adjacent to the inner side of the insulative panel.

3. The building wall structure of claim 2, wherein the film comprises aluminum.

4. The building wall structure of claim 1, further comprising an inner sheet positioned at a distance away from the inner side of each frame member so as to cause substantially stagnant air to be juxtaposed between the inner sheet and the insulative barrier.

5. The building wall structure of claim 1, wherein each insulative panel is made of polystyrene.

6. The building wall structure of claim 1, wherein each insulative panel is made of urethane.

7. The building wall structure of claim 1, wherein the first thickness equals approximately four inches.

8. The building wall structure of claim 1, wherein the frame members include a plurality of rafters and studs, the rafters positioned atop the studs, wherein the insulative barrier is positioned atop the rafters.

9. The building wall structure of claim 1, wherein each second fastener is attached to the second portion of the respective attachment member.

10. The building wall structure of claim 1, further comprising a plurality of expansion strips, each partially embedded within at least two insulative panels, wherein at least one second fastener is attached to the respective expansion strip.

11. The building wall structure of claim 7, wherein each insulative panel has a width of approximately two feet and a height of approximately six feet.

12. The building wall structure of claim 8, wherein the attachment members include a plurality of eave brackets, individually positioned adjacent to an intersection of the rafters and studs such that the first portion of the typical eave bracket is attached to a rafter and at least one second fastener is attached to the second portion of the eave bracket.

13. The building wall structure of claim 8, further comprising at least one bat, which is positioned at an intersection of at least two insulative panels, wherein roofing material is attached to the at least one bat.

14. The building wall structure of claim 13, wherein the at least one bat causes the roofing material to be separated at a second distance from the insulative panels.

15. The building wall structure of claim 14, wherein the second distance is equal to 0.5 inches.

16. The building wall structure of claim 1, wherein each attachment member includes at least opening through which at least one first fastener attaches the attachment member to a frame member.

17. The building wall structure of claim 16, wherein the at least one opening is surrounded by a dimple.

18. The building wall structure of claim 1, wherein each attachment member comprises at least one opening so as to remove thermally conductive material therefrom and consequently reduce thermal energy transfer through the attachment member.