THERMAL STUD OR PLATE FOR BUILDING WALL

Abstract

A metal thermal stud/plate has a center web with geometrically-shaped apertures spaced longitudinally along its centerline. The apertures define alternatingly-positioned narrow necks of material therebetween near ends of the center web. The narrow necks minimize thermal conductivity between the spaced flanges, but adjacent ones of the narrow necks are longitudinally misaligned due to their alternating positions to thus prevent forming a weak longitudinally-extending fold line in the stud/plate, thus maintaining its strength. In one form, the narrow necks are at most about 0.100 inches wide without substantially degrading the strength of the studs/plates, or can be a ratio of neck width to center web of as low as 0.09:4 down to 0.03:4. A building wall frame includes a plurality of the metal studs/plates and foam insulated panels with edges engaging the center webs of adjacent studs/plates to thus stabilize the metal studs/plates.

Description

BACKGROUND

The present invention relates to structural beams, such as metal studs or plates, configured for strength and thermal non-conductivity and suitable for use in building walls. The invention further relates to a method and apparatus for assembling a thermally insulated building structure.

Residential and other building structures are often constructed by erecting a frame consisting of wooden two by fours and other wood lumber. Insulation, sheet rock, and siding are attached to the frame. However, wood has disadvantages, such as being susceptible to termite and insect damage, and warping after it is installed. Also, wood shortages are increasing the expense of wood-frame buildings, and installation is labor intensive.

Another construction technique utilizes metal studs to construct walls. However when metal studs are used in a building wall (especially an exterior wall) or floor, thermal loss through the stud can be significant. Prior art thermal studs are known which include large apertures in their center web. However, in known studs, the narrow points which minimize thermal transfer are aligned and thus weaken the stud by creating a “fold line” weakness in its center web that extends longitudinally in the stud. Further, the “fold line” weakness reduces the stud's strength and/or limits a narrowness of the narrow points, which in turn limits the ability to minimize thermal conductivity through the studs.

SUMMARY OF THE PRESENT INVENTION

I have discovered that building structural components, such as plates, studs, and beams, can have a significantly increased thermal insulating value without sacrificing beam strength by forming narrowed necks of material along longitudinally misaligned positions.

In one aspect of the present invention, a thermal structural component for buildings includes a metal structural component, such as a stud or plate, having a center web and spaced flanges forming one of an I-beam shape, channel shape, or a C-beam shape. The center web includes a longitudinal centerline and includes geometrically-shaped apertures spaced longitudinally along the centerline, the apertures each extending onto both sides of the centerline and including first and second portions that define different shapes relative to the centerline and that are in alternating positions on opposite sides of the centerline in each successive aperture. The first and second portions of adjacent ones of the apertures define at least one narrow neck of material therebetween that is located near a flange-adjacent end of the center web. The narrow necks minimize thermal conductivity between the spaced flanges, but adjacent ones of the narrow necks are longitudinally misaligned due to their alternating positions to thus prevent forming a weak longitudinally-extending fold line in the structural component such that a strength of the structural component is substantially maintained.

In another aspect of the present invention, a thermal structural component for buildings includes a metal structural component, such as a stud or plate component, having a center web and spaced flanges forming one of an I-beam shape, channel shape, or a C-beam shape. The center web includes apertures spaced along the center web that define therebetween a series of narrow necks of material located in an outer 25% of the center web. The series of narrow necks are located at alternating ends of the center web and minimize thermal conductivity between the spaced flanges, but the narrow necks are longitudinally misaligned and located near the spaced flanges to prevent forming a weak longitudinally-extending fold line in the structural component. By this arrangement, a strength of the structural component is substantially maintained.

In another aspect of the present invention, a thermal structural component for buildings includes a metal structural component, such as a stud or plate component, having a center web and spaced flanges forming one of an I-beam shape, channel shape, or a C-beam shape. The center web includes apertures along the center web that define therebetween repeating narrow necks of material located in the center web, the narrow necks being at most about 0.100 inches wide and substantially minimizing thermal conductivity between the spaced flanges, but the narrow necks being longitudinally misaligned to prevent forming a weak longitudinally-extending fold line in the structural component and to thus substantially maintain a strength of the structural component.

In another aspect of the present invention, a thermal structural component for buildings includes a metal structural beam component having a center web and spaced flanges forming one of an I-beam shape, channel shape, or a C-beam shape; the center web including apertures spaced longitudinally along the center web that define therebetween a series of narrow necks of material, adjacent ones of the narrow necks defining a fold line that is at least 45 degrees angled to a length of the stud, the apertures with narrow necks substantially minimizing thermal conductivity between the spaced flanges, but the narrow necks being longitudinally misaligned to prevent forming a weak longitudinally-extending fold line that extends parallel the length of the beam component, such that the arrangement substantially maintains the strength of the beam component.

In another aspect of the present invention, a thermal structural component for buildings includes a metal structural beam component having a center web and spaced flanges forming one of an I-beam shape, channel shape, or a C-beam shape; the center web including a series of repeated apertures, some inverted from others and each spaced longitudinally along the center web, with sections of material remaining in the center web defining therebetween a series of triangular truss-simulating sections of material extending between edge portions of the center web.

In another aspect of the present invention, a thermal structural component for buildings includes a metal structural beam component having a center web and spaced flanges forming one of an I-beam shape, channel shape, or a C-beam shape; the center web including apertures that define alternatingly positioned narrow necks that minimize heat transfer but maintain structural strength of the beam component. In a narrower form, a width of the narrow neck is at most about 0.100 inches.

In a narrower aspect of the present invention, the necks have a first width, and the center web has a second width, a ratio of the first width to the second width being at most about 0.25 to 4, or more preferably the ratio is at most about 0.1 to 4, or even as low as between 0.09 to 4 down to 0.03 to 4.

In a narrower aspect of the present invention, at least some of the apertures are polygonal shaped and each include first flat sides extending parallel a first one of the spaced flanges, and include second flat sides extending at an angle to a second of the spaced flanges.

In one aspect of the present invention, a building wall frame includes a plurality of thermal structural components as defined in any of the above concepts, the components being spaced apart but arranged to define a wall; and a plurality of structural insulated panels with edges engaging the center webs of adjacent components and including front and rear faces engaging an inside of the flanges of the components in a manner stabilizing the components in the assembly.

These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF DRAWINGS

FIGS. 1 and 1A are side and end views of a first embodiment of the present inventive concepts.

FIGS. 1B and 1C are end views of alternative beam shapes.

FIGS. 2-4 are side views of modified beams embodying the present concepts.

FIGS. 5 and 5A are fragmentary perspective views showing a building wall using the studs of FIG. 1 in combination with structural insulated panels.

FIG. 6 is a perspective view of a frame for a building wall (with the structural insulated foam panels removed to more clearly show the beams), and with FIGS. 6A-6B showing cross sectional shapes of the horizontal top plate and vertical studs, the horizontal lower plate having a cross section similar to the top plate.

FIG. 7 is an exploded perspective view of an assembly of top and bottom plates to a structural insulated panel (SIP), and FIG. 7A is a vertical cross section through the assembly.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present metal thermal structural component for buildings (also called a “beam” or “stud” or “plate” herein) includes apertures (i.e. cut-outs) in its center web configured to minimize thermal transfer laterally across the stud while still maximizing a strength of the center web and of the stud. It is contemplated that the discussion regarding one illustrated product, such as studs 30-30D (FIG. 1), applies equally to other products, such as plates 60, 60A, 61, 61A (FIGS. 6-7). The thermal structural components are preferably made of metal, such as steel or aluminum, and are preferably galvanized or coated for corrosion resistance. They have a center web with geometrically-shaped apertures spaced longitudinally along its centerline CL, the apertures being shaped to define alternatingly-positioned narrow necks of material therebetween near flange-adjacent ends of the center web. The narrow necks minimize thermal conductivity between the spaced flanges, but adjacent ones of the narrow necks are longitudinally misaligned due to their alternating positions along the structural components to thus prevent forming a weak longitudinally-extending fold line in the component, so that the component's strength is substantially maintained.

In one form, such as in a stud used in exterior building walls, the narrow necks are less than 0.25 inches in a 2×4 stud, such as at most about 0.100 inches wide without substantially degrading a strength of the studs, or can be a ratio of neck width to center web of as low as 0.09:4 down to 0.03:4. In some applications, the neck can be elongated to further decrease thermal conductivity and/or additional apertures can be added in the center web. A building wall frame includes a plurality of the metal studs and structural insulated panels (sandwich construction of foam core and rigid skin) with edges of the panels engaging the center webs and flanges of adjacent studs to thus stabilize the metal studs. Also, the building wall includes horizontal members (often called “plates”) that extend along a length of the wall at top and bottom edges of the structural insulated panels.

The present illustrated metal stud 30 (FIG. 1) has a high thermal insulated value due to the narrow necks 35, which can be less than 0.100 inches in width. The metal stud 30 includes a center web 31 connecting flanges 32 and 33 to form a C-shaped beam (or alternatively, could be an I-shaped beam, FIG. 1B or channel shape, FIG. 1C). Diamond-shaped apertures 34 are cut out of the center web 31 in alternating inverted positions on the centerline CL, such that the apertures 34 form an alternating pattern of the narrow necks 35 of material near the flanges 32 and 33, with the necks substantially “choking” off and limiting thermal conduction across the beam. The necks 35 are positioned about 0.75 inches from the adjacent flanges 32 or 33. The illustrated diamond shaped apertures 34 have equal sides that extend about 2.5 inches, two sides extending parallel the flanges 32 and 33, and the others extending at about 45 degrees relative to the flanges. Notably, it is contemplated that the apertures can be other shapes than diamond-shapes (e.g. longitudinally elongated rhomboid shapes) depending on the functional requirements of the application.

As a result of the non-aligned position of the necks 35, the narrow necks 35 can be surprisingly narrow without substantially weakening a structural bending strengths of the stud 30, yet providing the stud 30 with a very high insulating value. Specifically, the non-aligned position of the narrow necks 35 causes the beam to maintain its strength, such as greater than 90% of its original “non-apertured” strength when the stud 30 is in a building wall (depending on a size of the neck and beam width, and its mating engagement with a structural insulated panel) despite the presence of the very narrow necks 35. Depending on the functional requirements of the studs 30, the narrow necks 35 can be as low as 0.10 inches in a 2×4 stud, or lower without adversely affecting its strength. For example, it is contemplated that a 2×4 stud can maintain sufficient strength in many applications when the narrow necks 35 are as low as 0.09 inches, or even lower at 0.06 inches, or still lower at 0.03 inches, where the necks 35 occur at a location about 0.75 inches from the flanges 32 and 33.

Additional embodiments of the present inventive stud are contemplated. In the additional embodiments, similar and identical features are identified using the same numbers, but with the addition of a letter “A”, “B”, or etc. The end views of the additional embodiments can be similar to any of FIGS. 1A-1C. The use of similar identification numbers is done for the purpose of reducing redundant discussion.

As noted above, the stud apertures are not limited to only diamond (or rhomboid) shapes. For example, the modified stud 30A (FIG. 2) includes alternatingly inverted triangular apertures 34A. The apertures form right triangles having orthogonal sides of 2.5 inches across and about 1.94 inches longitudinally, but of course other triangular shapes can be used. Further, a modified stud 30B (FIG. 3) includes alternating polygonal apertures 34B and additional apertures 34B′ in the remaining material of the center web between the apertures 34B to create elongated necks 35B, with pairs of the necks 35B extending to define a triangular pattern or X shaped pattern. Also, a length of the apertures 34B can be extended longitudinally, as shown by stud 30D (FIG. 4), which includes elongated apertures 34D, 34E and 34E′. Each of the above illustrated apertures are polygonal shapes with flat sides, but it is contemplated that a scope of the present invention includes other geometrically-shaped apertures. In a preferred form, the material of the stud is 18 to 29 gauge galvanized metal (light gauge metal), though the present invention is not limited to only that material or thickness.

The illustrated necks have a first width, and the center web has a second width, a ratio of the first width to the second width being at most about 0.25:4, or more preferably the ratio is at most about 0.1:4, or even as low as between 0.09:4 down to 0.03:4. At least some of the studs include apertures that are polygonal shaped, where each aperture includes first flat sides extending parallel a first one of the spaced flanges, and includes second flat sides extending at an angle to a second of the spaced flanges, such as at an angle of between 45 and 70 degrees, or more preferably 45 to 60 degrees. In several embodiments, the necks are elongated to have a continued narrow width extended at least about 0.25 inches. In some embodiments, a pair of the elongated necks form strips that extend in a truss-simulating triangular arrangement. (See FIGS. 3 and 4.) In some embodiments, additional apertures are added to further reduce thermal conductivity of the beams. (See FIGS. 3-4.) In some embodiments, the necks and/or the leg-like supporting structure (studs 38B and 38D) opposite the necks are elongated and tapered in length, such as having one (inner) edge of the leg extending at 60 degrees and an opposite (outer) edge extending at 70 degrees. (See FIGS. 3 and 4.)

In one aspect of the present invention, a building wall frame 50 (FIG. 5) includes a plurality of metal studs 30 (or 30A-30D) as defined above, the studs 30 being spaced apart but arranged to define a wall. A plurality of structural insulated panels 51 (each having a foam core and rigid facings) are attached by screws 56 (or nails/fasteners) to the studs 30 with edges 52 of the panels 51 engaging the center webs 31 of adjacent studs 30 and with the panel's front and rear faces 53 and 54 engaging an inside of the flanges 32 and 33 of the studs 30. Also, it is noted that studs 30 can be connected together, such as by fasteners 59 or welds. Thus, the insulated panels 51 engage the metal studs 30 in a manner that stabilizes the metal studs 30, thus further strengthening the wall frame 50. Notably, structural insulated panels such as panels 51 are known in the art, such as is shown in Porter U.S. Pat. Nos. 4,135,497 and 4,119,750, the entire contents of which are incorporated herein for their teachings.

FIG. 6 is a perspective view of a frame for an exterior building wall 50A (with the structural insulated foam panels 51 removed to more clearly show the beams). Top and bottom plates 60 and 61 (FIG. 6A) are interconnected to perpendicularly extending studs 30E (or 30A-30B) by screws or fasteners 62 (FIG. 6). A cross section of the plates 60 and 61 are shown in FIG. 6A. Studs 30E are similar to studs 30-30D, but include an inward lip on each flange (see FIG. 6B).

FIG. 7 is an exploded perspective view of the building wall 50A showing an assembly of top and bottom plates to a structural insulated panel (SIP) with the studs removed for clarity. FIG. 7A is a vertical cross section through the assembly of FIG. 7, and shows attachment of the assembly (studs 30E and plates 60 and 61) to a bottom support 63 (e.g. floor) and overhead structure 64 (e.g. to of wall).

It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.

Claims

1. A thermal structural component comprising:

a metal structural beam component having a center web and spaced flanges forming one of an I-beam shape, channel shape, or a C-beam shape, the center web including a longitudinal centerline and including geometrically-shaped apertures spaced longitudinally along the centerline, the apertures each extending onto both sides of the centerline and including first and second portions that define different shapes relative to the centerline and that are in alternating positions on opposite sides of the centerline in each successive aperture, the first and second portions of adjacent ones of the apertures defining at least one narrow neck of material therebetween that is located near a flange-adjacent end of the center web, the narrow neck minimizing thermal conductivity between the spaced flanges, but adjacent ones of the narrow necks being longitudinally misaligned due to their alternating positions to thus prevent forming a weak longitudinally-extending fold line in the beam component such that a strength of the beam component is substantially maintained.

2. The thermal structural component as defined in claim 1, wherein the necks have a first width, and the center web has a second width, a ratio of the first width to the second width being at most about 0.25:4.

3. The thermal structural component as defined in claim 2, wherein the ratio is at most about 0.1:4.

4. The thermal structural component as defined in claim 3, wherein the ratio is at most about 0.06:4.

5. The thermal structural component as defined in claim 1, wherein a width of the narrow necks is at most 0.1 inches.

6. The thermal structural component as defined in claim 1, wherein at least some of the apertures are polygonal shaped and each include first flat sides extending parallel the spaced flanges, and include second flat sides extending at an angle to the spaced flanges.

7. The thermal structural component as defined in claim 6, wherein the angle is between about 45 and 60 degrees.

8. The thermal structural component as defined in claim 1, wherein the apertures are a repeating pattern of triangular shapes positioned in alternatingly inverted positions.

9. The thermal structural component as defined in claim 1, wherein the apertures are a repeating pattern of quadrilateral shapes positioned in alternatingly inverted positions.

10. The thermal structural component as defined in claim 1, wherein the necks are elongated and define a narrowed length of at least about 0.25 inches long.

11. The component defined in claim 1, wherein at least one of the center web and flanges further includes small holes for receiving fasteners, such as nails or screws, for securing the component to another structure.

12. A building wall frame comprising:

a plurality of thermal structural components as defined in claim 1, the components being spaced apart but arranged to define a wall; and

a plurality of structural insulated panels extending between the components, the panels having edges engaging the center webs of adjacent components and including front and rear faces engaging an inside of the flanges of the components, the insulated panels engaging the thermal structural components to stabilize the thermal structural components in the wall arrangement.

13. A thermal structural component comprising:

a metal structural beam component having a center web and spaced flanges forming one of an I-beam shape, channel shape, or a C-beam shape, the center web including apertures spaced along the center web that define therebetween a series of narrow necks of material located in an outer 25% of the center web, the series of narrow necks being located at alternating ends of the center web and minimizing thermal conductivity between the spaced flanges, but the narrow necks being longitudinally misaligned and located near the spaced flanges to prevent forming a weak longitudinally-extending fold line in the beam component such that a strength of the beam component is substantially maintained.

14. The thermal structural component as defined in claim 13, wherein the necks have a first width, and the center web has a second width, a ratio of the first width to the second width being at most about 0.25:4.

15. The thermal structural component as defined in claim 14, wherein the ratio is at most about 0.1:4.

16. The thermal structural component as defined in claim 13, wherein at least some of the apertures are polygonal shaped and each include first flat sides extending parallel the spaced flanges, and include second flat sides extending at an angle to the spaced flanges.

17. The thermal structural component as defined in claim 13, wherein the apertures are a repeating pattern of triangular shapes positioned in alternatingly inverted positions.

18. The thermal structural component as defined in claim 13, wherein the apertures are a repeating pattern of quadrilateral shapes positioned in alternatingly inverted positions.

19. The component defined in claim 13, wherein at least one of the center web and flanges further includes small holes for receiving fasteners, such as nails or screws, for securing the component to another structure.

20. A thermal structural component comprising:

a metal structural beam component having a center web and spaced flanges forming one of an I-beam shape, channel shape, or a C-beam shape; the center web including apertures spaced longitudinally along the center web that define therebetween a series of narrow necks of material, adjacent ones of the narrow necks defining a fold line that is at least 45 degrees angled to a length of the stud, the apertures with narrow necks substantially minimizing thermal conductivity between the spaced flanges, but the narrow necks being longitudinally misaligned to prevent forming a weak longitudinally-extending fold line that extends parallel the length of the beam component, such that the arrangement substantially maintains the strength of the beam component.

21. The component defined in claim 20, wherein at least one of the center web and flanges further include small holes for receiving fasteners, such as nails or screws, for securing the component to another structure.

23. A thermal structural component comprising:

a metal structural beam component having a center web and spaced flanges forming one of an I-beam shape, channel shape, or a C-beam shape; the center web including a series of repeated apertures, some inverted from others and each spaced longitudinally along the center web, with sections of material remaining in the center web defining therebetween a series of triangular truss-simulating sections of material extending between edge portions of the center web.

24. A thermal structural component comprising:

a metal structural beam component having a center web and spaced flanges forming one of an I-beam shape, channel shape, or a C-beam shape; the center web including apertures that define alternatingly positioned narrow necks that minimize heat transfer but maintain structural strength of the beam component.

25. The component defined in claim 24, wherein the necks have a width of less than about 0.1 inches.