CONSTRUCTION FRAMING MEMBER WITH INTEGRATED THERMAL BREAK AND METHOD FOR MANUFACTURING SAME

Abstract

A construction framing member comprising a framing member and an insulative material disposed in a channel within the framing member. Thermal bridging properties of finished walls constructed with the product are altered positively, by incorporation of the thermal break in the finished wall created by the insulative material within the framing members. A method of manufacturing the construction framing member is disclosed—a channel is created in an integral framing member using a saw, router or the like, for the placement of the insulative material.

Description

FIELD OF THE INVENTION

The present invention relates to building construction materials, and more particularly to construction materials with enhanced insulative properties.

BACKGROUND OF THE INVENTION

Improvements in building construction materials and methods are constantly sought to enhance the comfort and economy of residential and commercial buildings.

One of the areas in which a large amount of effort is currently concentrated is in the development of alternate materials and construction methods to increase energy efficiency. Heating a building is negatively impacted if the building is not properly sealed and insulated; gaps in the structure of the building as well as thin, non-insulated walls allow heat to transfer out of the building and increase heating costs, as well as result in uneven heating levels within the building.

In addition to the increased cost of energy for heating the building, there is also undue damage to the environment due to the increased amounts of heating fuel or energy which are consumed to keep these buildings at comfortable temperatures. As such it is desirable to provide or enhance the effect of insulation in the walls of buildings to prevent or minimize heat loss.

Typical walls of a building are manufactured with dimensional lumber or other stud materials, having a gypsum or other type of wall board on the interior of the building. Vapor barrier may also be used between the interior wall surface and the studs or dimensional framing members which provide structure to the wall in the building. The studs act as an inner member framework which, along with providing structure and support for the wall itself, also support wall coverings, windows and doors. They also provide mounting cavities or mounting surfaces for electrical wiring, plumbing, HVAC systems and other utilities.

Standard dimensional lumber or other aluminum or steel stud materials are often used to construct these walls. Most often interior walls are generally constructed with 2 inch×4 inch wall studs, although sometimes 2 inch×6 inch wall studs would be used to provide more strength. Typically the studs or framing members are placed a predefined standard spacing apart, for example either every 16 or 24 inches. Extra studs can be used or provided wherever walls intersect, or to provide a nailing area or additional support.

Batts of insulation would typically be installed in the spaces between framing members inside a wall to provide insulation and reduce heat loss through the cavities between the framing members. To the exterior of a building wall there is often an air barrier and some kind of an exterior surface or siding which is attached through to the studs.

Insulation batts are important in providing insulation in the areas of the cavities between the framing members. Some common forms of insulation hafts are made from fiberglass, mineral wool, or cotton. These batts are fibrous sheets that arc long and wide enough to fit snugly between wall studs. Another form of insulation is loose-fill insulation, which is a light fibrous fill. This type of insulation is laborious to install and typically requires a professional installer. Furthermore, this type of insulation is easily affected by air movement. There is also spray-applied insulation that can fill cavities very well, but again, must be applied by a specialized contractor.

An effective insulation system will prevent the movement of air through the system. If there are any cavities, they will be filled with insulation, leaving no gaps in or around the insulation. The structural members in the wall oftentimes act as thermal bridges, extending from the warm side of the insulation to the cold side of the insulation, allowing for an easy escape of heat. While insulation batts installed in the cavities between the framing members provide some insulation to a building, the framing members or studs of the wall allow heat transfer to occur from the warm side to the cool side of the wall through the framing members themselves. This problem is further emphasized with the use of metal member portions instead of wood, because much more heat flows through metal studs and joists than through pieces of wood.

There have been many attempts to prevent heat loss through thermal bridges such as the framing members. One of the most popular methods of preventing this type of heat loss is to provide some type of rigid, board-stock insulation on the exterior face of the studs, usually expanded polystyrene or insulation batts. However, installation of this type of insulation on all the exterior faces of the studs involves wrapping the entire house with a rigid foam batt, or similar type of insulation product, which is very expensive and labour intensive. Again, this type of material can also be an irritant or hazardous during installation and will often require professional installation.

Another attempt to minimize this type of heat loss is to space the wall studs at 24 inches apart, rather than 16 inches apart. This extra spacing between the studs reduces the total number of studs in the wall, thus reducing the surface area of the framing members available for heat transfer. However, the reduction in the number of total framing members reduces the strength of the wall. As such, it is not desirable to reduce the number of framing members, if possible. Furthermore, the reduction in framing members does not eliminate, or even minimize, the heat loss that will occur through the remaining framing members.

A further attempt to minimize heat loss through wall studs uses a method of staggering the wall studs that appear next to one another. A first wall stud would be situated against the inner wall leaving a gap between the first wall stud and the outer wall, and a second wall stud adjacent the first wall stud would be situated against the outer wall leaving a gap between the second wall stud and the inner wall, whereby the wall studs would alternate positions as such along the wall. In this way, a given stud will not concurrently contact the materials of the inner wall and the materials of the outer wall, and will consequently be unable to transfer heat directly from the inner wall, through to the stud, to the outer wall and out of the building. However, there are many drawbacks associated with this method, as well. This method of reducing heat loss through studs is very labor intensive and expensive, as each stud needs to be perfectly placed in relation to the studs next to it. This furthermore increases the thickness of the wall and reduces the strength of the wall since each of the inner wall and the outer wall are only provided with one half of the number of wall studs for support.

What is needed, therefore, is a construction framing member that has enhanced thermal insulative properties but is capable of manufacture using relatively simple methods that do not introduce undue complexity.

SUMMARY OF THE INVENTION

The present invention seeks to provide a construction framing member that comprises standard material but incorporates a thermal break in the form of an insulative material.

According to a first aspect of the present invention there is provided a framing member for use in the manufacture of a construction framing member, the framing member including a channel for receiving insulative material. The framing member is preferably composed of wood and the channel is preferably a channel running substantially the length of the framing member and exposed at the surface of the framing member at one edge thereof, and extending through the majority of the thickness of the member.

According to a second aspect of the present invention there is provided a construction framing member that comprises a framing member comprising a channel, and an insulative material situate in the channel. The insulative material has a lower thermal conductivity than the framing member which houses it and therefore increases the thermal insulation properties of the construction framing member.

According to a third aspect of the present invention there is provided a method of manufacturing a framing member comprising the steps of: (a) providing a length of wood suitable to be used as a framing member, the length of wood having a depth; (b) providing a wood-cutting tool having a cutting implement with an operative length less than the depth; and (c) cutting a channel in the length of wood in the direction of the depth using the cutting implement to form the framing member, such that the channel penetrates into the length of wood to less than the depth. The wood-cutting tool may be a table saw or router or any other similar tool known in the art, and the cutting implement would then be a blade or bit or similar cutting implement, respectively, which can be set to a length that is less than the depth, such that when the cutting of the channel is completed a portion of wood still remains intact beyond the set reach of the cutting implement. There could also be a purpose built machine for this purpose, which would cut the channel in the wood and then in a following step place insulative material in the channel (by rolling a rolled insulation into the channel, foaming a ply insulation into place or the like).

According to a fourth aspect of the present invention there is provided a method of manufacturing a construction framing member comprising the steps of: (a) providing a length of wood suitable to be used as a framing member, the length of wood having a depth; (b) providing a wood-cutting tool having a cutting implement with an operative length less than the depth; (c) cutting a channel in the length of wood in the direction of the depth using the cutting implement to form a framing member, such that the channel penetrates into the length of wood to less than the depth; (d) providing an insulative material; and (e) introducing the insulative material into the channel to form the construction framing member. The insulative material may be either a solid component sized to fit in and preferably fill the channel, or a foam or other liquid insulative material that can be injected into the channel to fill the channel, wherein upon solidification of the insulative material in the channel the construction framing member is formed.

BRIEF DESCRIPTION OF THE DRAWINGS

While the invention is claimed in the concluding portions hereof, preferred embodiments are provided in the accompanying detailed description which may be best understood in conjunction with the accompanying diagrams where like parts in each of the several diagrams are labeled with like numerals, and where:

FIG. 1a is a perspective view of a framing member in accordance with the present invention;

FIG. 1b is a top plan view of the framing member of FIG. 1a;

FIG. 1c is a side elevation view of the framing member of FIG. 1a;

FIG. 2 is a perspective view of a construction framing member according to the present invention; and

FIG. 3 is a flow chart showing the steps of one embodiment of the method of manufacture of the construction framing member of the present invention.

The present invention will now be described with reference to the accompanying drawings of illustrated embodiments.

DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENTS

The following discussion provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements.

Generally speaking, the inventive concept consists of the placement of an insulated thermal break into a dimensional construction framing member. The insulation provides a thermal break in assembled walls using the member, while providing some rigidity and structural integrity to the member as well. By placing the insulation in a channel that extends through most but not all of the depth of the member, streamlined manufacturing options are presented, resulting in enhanced economy and a novel improvement over the prior art.

Referring now in detail to FIGS. 1a to 1c, a framing member 10 according to the present invention is illustrated. The framing member 10 is a construction framing member 34, as will be described below. The framing member 10 comprises a channel 12 which in the exemplary embodiment extends the length of the framing member 10; it will be clear to one skilled in the art that the channel 12 need not extend the entire length of the framing member 10 in order to enhance the insulative properties of the framing member 10, but having a relatively continuous channel 12 along the entire length will optimize such properties and streamline manufacturing. This channel 12 is for the receipt of insulative material 32, as will be described below. The framing member 10 is preferably composed of wood, due to the ease with which the channel 12 can be cut out of a wooden substrate and the utility of wooden framing members in construction contexts.

The framing member 10 comprises a first section 14 and a second section 16, separated by the channel 12 which extends inwardly from the outer surface 30 of the framing member 10. As the channel 12 does not pass completely through the framing member 10, a thin remainder of material connects the first and second sections 14, 16, namely the connecting section 18. The channel 12 is therefore only exposed in the exemplary embodiment at the outer surface 30 and opposed first and second ends 26, 28 of the framing member 10.

The channel 12 is preferably a channel running substantially the length of the framing member 10 and exposed at the outer surface 30 of the framing member 10, and it is defined by the inner surface 20 of the first section 14, the inner surface 22 of the second section 16 and the inner surface 24 of the connecting section 18.

Turning now to FIG. 2, a construction framing member 34 according to the present invention is illustrated. The construction framing member comprises the framing member 10, with an insulative material 32 disposed within the channel 12. In this way, the original dimensions of the lumber are maintained but with the presence of a thermal break incorporated within the construction framing member 34 to enhance the insulative properties of the building material.

The manufacture of a framing member 10 in accordance with the present invention can be accomplished using known tools and methods of woodworking. First, a length of wood suitable for use as a framing member is provided, and this may be a standard 2 inch×4 inch or 2 inch×6 inch piece of lumber that is commonly used in construction and therefore will likely be of suitable dimensions for the building plans. This length of wood will have a standard depth, 2 inches in most cases. Next, a standard wood-cutting tool such as a table saw or router table is provided, the wood-cutting tool having a cutting implement. This cutting implement (a saw blade in the case of a table saw, or a router bit in the case of a router table) can be set at a desired height above the work surface of the tool, and in the case of a length of wood having a depth of 2 inches the desired cutting implement height setting is preferably approximately 1¾ inches, although the height setting can be any length less than 2 inches. With the operative height of the cutting implement set at less than the depth of the piece of lumber, the user then cuts a channel 12 in the length of wood in the direction of the depth using the cutting implement in a manner well known to those skilled in the art, such that the channel 12 penetrates into the length of wood to less than the depth. When the cutting of the channel 12 is completed, a portion of wood still remains intact beyond the set reach of the cutting implement, specifically the connecting section 18. The width of the channel 12 can vary as needed given the predetermined insulative properties that the final construction framing member is to have, and one skilled in the art will know how to use various wood-cutting tools to achieve channels 12 of varying widths.

Whereas the insulative material 32 could be introduced in any number of ways, including cutting a piece of solid insulation to the size of the channel 12 and fixing it in place (by glue or other known means) between the first and second sections 14, 16, it is preferable to use polyurethane foam insulation as the insulative material 32 and inject same into the channel 12. Once the injected foam insulation has hardened, the waste can be cut away such that the outer surfaces of the insulative material 32 are flush with the outer surface 30, first end 26 and second end 28 of the framing member 10. The width of the insulative material 32 can be generally between ½ inch and 1 inch, although the width could vary depending on the heat conductivity of the particular insulative material 32 and the thickness required to obtain the desired degree of insulation. Where the construction framing member 34 is secured in place in a wall, with the first section 14 disposed toward the building interior and the second section 16 disposed toward the outside of the building, heat transfer can be minimized from the first section 14 of the framing member 10 to the second section 16 of the framing member 10, thus reducing the thermal bridge between the inner wall and the outer wall of the building.

It should also be noted that the above description is of one exemplary embodiment only as illustrated by the accompanying Figures, and the size of the first section 14, second section 16 and insulative material 32 could each be adjusted for a number of reasons. For example, the insulative material 32 could be thickened or thinned based upon the particular thermal requirements of the application in which the construction framing member 34 when assembled would be used. Also, the first and/or second sections 14,16 might be sized appropriately such that their utility in conventional construction techniques would be maximized, e.g. such that they would still most strongly support fasteners attached thereto, etc. In one embodiment, the complete construction framing member 34, including the first and second sections 14, 16 plus the integrated insulative material 32 could in total be approximately the same size as a standard dimensional framing member, for example in total being the approximate dimensions of a standard 2 inch×4 inch or 2 inch×6 inch framing member, such that it could be easily interchanged into pre-existing construction methods and market acceptance of the product could be maximized. It will be understood by one skilled in the art that there is no specific ideal set of dimensions for the construction framing member 34 of the present invention but that any number of different pre-existing dimensional lumber sizes could be duplicated using the construction framing member 34.

FIG. 3 is a flow chart demonstrating the steps in one embodiment of the method of manufacture of the present invention. As outlined above, the base or substrate for the construction framing member of the present invention is a dimensional piece of framing lumber, which would be typically used in the production or manufacturable wall or other structure requiring the integration of the thermal break therein. The first step in the method shown in this embodiment is to provide a cutting tool which could machine the channel 12 as outlined elsewhere herein into the substrate or framing member 34. In some cases this could comprise a table saw, a guided router or the like, or in other circumstances of purpose built machine for the manufacturer of the construction framing member of the present invention can be provided which was capable either in fixed or adjustable fashion of cutting the desired channel into the framing member or substrate, through some but not all of its depth, into which insulating material could be adhered. The cutting machine which would machine the channel into the framing member would include one or more guides common offenses or the like to guide the framing member in appropriate relation to the cutting tool for the formation of the channel. Step 3-1 shows the provision of the cutting tool.

A framing member would be fed into and through the cutting tool, resulting in the kind of a channel into the framing member extending through the majority of the depth of the framing member along substantially all of its length, and across a portion of its width. Cutting of the channel into the framing member is shown at step 3-2.

Following the cutting of the channel into the framing member, shown at 3-2, insulating material would be placed and adhered into the channel, forming the thermal break in the finished construction framing member. The specific nature of this insulation placement and adhesion step, 3-3, will depend upon the nature of the insulating material to be used. In some cases channel may be cut to the same size of precut or pre-manufactured insulating members which could simply be placed and glued into the channel, or in other cases rolled insulation could be placed into the channel and adhered. It is specifically contemplated that in some embodiments of the method of manufacture, the insulating material which will be used would be foamed polymeric insulation, which could simply be injected into the channel as the framing member passed out of the cutting tool, such that it would expand to fill the channel and potentially be trimmed or otherwise cosmetically finished, to yield the finished construction framing member.

It is specifically contemplated that a machine for the practice of the entirety of this method could be developed in a circumstance where it was decided to produce large quantities of the construction framing member of the present invention, and any machine which would accomplish the steps of guiding a framing member through the cutting of the channel therein, and the subsequent placement and adhesion of insulating material within the channel, is also contemplated within the scope of the present invention. As can also be seen, the manufacturer of the product of the present invention could be done in a reasonably continuous process particularly where purpose built machine for the combined coming of the channel and placement and adhesion of the insulative material was produced, or a combination of equipment was placed in line to work in such a continuous feeding fashion. Again, any machine which allowed for the guided kind of a channel until framing member and the subsequent placement and adhesion of an insulated thermal break therein, otherwise in accordance with the remainder of the present invention outlined herein, is explicitly contemplated within the scope of the present invention.

As can be readily seen, then, the framing member and construction framing member of the present invention present significant advantages over the prior art. Enhanced thermal insulation properties are provided in a product that can be manufactured in industry standard sizes for case of implementation. There is no need to implement a novel stud arrangement or spacing that may weaken the structure, but rather the structural strength of wood is maintained while integrating a thermal break.

The foregoing is considered as illustrative only of the principles of the invention. Thus, while certain aspects and embodiments of the invention have been described, these have been presented by way of example only and are not intended to limit the scope of the invention. It will be apparent to those of skill in the art that by modification the present invention can be optimized for use in a wide range of conditions and applications. It will also be obvious to those of skill in the art that there are various ways and designs with which to produce the apparatus and methods of the present invention. The illustrated embodiments are therefore not intended to limit the scope of the invention, but to provide examples of the apparatus and method to enable those of skill in the art to appreciate the inventive concept.

Claims

1. A construction framing member with improved thermal insulation properties, comprising:

a. a framing member having a length, a width and a depth, capable of use in a traditional construction framing function;

b. a channel formed in the framing member, the channel having a length, a width and a depth and being sized such that: i. the length of the channel runs substantially the length of the framing member; ii. the depth of the channel is less than the depth of the framing member; and iii. the width of the channel is less than the width of the framing member; and

c. insulating material adhered within the channel, said insulating material effective to reduce thermal transfer across the width of the framing member.

2. The construction framing member of claim 1 wherein the depth of the channel is at least 50% of the depth of the framing member.

3. The construction framing member of claim 1 wherein the depth of the channel is at least 80% of the depth of the framing member.

4. The construction framing member of claim 1 wherein the width of the channel is less than 50% of the width of the framing member.

5. The construction framing member of claim 1 wherein the insulating material comprises at least one of fiberglass, mineral wool, cotton, a foam, a solid insulating material, or an injectable self-solidifying liquid.

6. The framing produce of claim 5 wherein the insulating material comprises a polymeric foam.

7. The construction framing member of claim 1 wherein the framing member is sized to have dimensions substantially the same as a standard lumber size of a lumber framing member.

8. The construction framing member of claim 1 wherein the channel is positioned such that the framing member is divided into a first section, a second section, and a connecting section, wherein the channel is positioned between the first section and second section and overlays the connecting section.

9. The construction framing member of claim 8 wherein the first section and sections have different widths.

10. A method of manufacturing a construction framing member with improved thermal insulation properties, comprising:

a. providing a framing member, the framing member having a length, a width and a depth;

b. forming a channel in the framing member which is configured to receive an insulating material, the channel having a length a width and a depth, wherein the channel is sized such that: i. the length of the channel runs substantially the length of the framing member; ii. the depth of the channel is less than the depth of the framing member; iii. the width of the channel is less that the width of the framing member; and

c. placing and adhering an insulating material in the channel such that the channel is substantially filled with the insulating material.

11. The method of claim 10 wherein the operation of forming the channel is performed by sawing or routing.

12. The method of claim 11 wherein the framing member is wood.

13. The method of claim 10 wherein the depth of the channel is least 50% of the depth of the framing member.

14. The method of claim 10 wherein the depth of the channel is at least 80% of the depth of the framing member.

15. The method of claim 10 wherein the width of the channel is less than 50% of the width of the framing member.

16. The method of claim 10 wherein the insulating material comprises at least one of fiberglass, mineral wool, cotton, a foam, a solid insulating material, or an injectable self-solidifying liquid.

17. The method of claim 16 wherein the insulating material is adhered in the channel using glue.

18. The method of claim 16 wherein the insulating material is self-adhering in the channel.

19. The method of claim 18 wherein the insulating material comprises a polymeric foam.

20. The method of claim 19 wherein the foam expands once placed in the channel to fill and adhere within the channel.

21. The method of claim 10 wherein the framing member is sized to have dimensions substantially the same as a standard lumber size of a lumber framing member.

22. The method of claim 10 wherein the channel is formed such that the framing member is divided into a first section, a second section, and a connecting section, where the channel is between the first section and second section, and overlays the connecting section.

23. The method of claim 22 wherein the first section and the second section have different widths.