Patent ID: 7168216
Filing Date: 2007-01-30
Classification: B29C,E04B,E04C,E04F,Y02A

Abstract:
1. A method of making a prefabricated stud panel, with the prefabricated stud panel comprising i) a first plate; ii) a second plate; iii) exterior sheathing, with the exterior sheathing having an inner face; iv) interior sheathing, with the interior sheathing having an inner face; v) a set of studs between the first and second plates and further between the exterior and interior sheathing, wherein the set of studs includes a pair of outer studs, wherein the set off studs includes a set of inner studs disposed inwardly of the outer studs, wherein each of the studs includes a width running in a direction from the exterior sheathing to the interior sheathing, and wherein the set of studs define a set of inner regions, with each of the inner regions being an area between one pair of adjacent studs, between the first and second plate of said one pair of adjacent studs, and between the exterior and interior sheathing of said one pair of adjacent studs; vi) and wherein the prefabricated stud panel includes a height direction defined by a direction between the first and second plates, a length direction defined by a direction between the outer studs, and a width direction defined by a direction between the exterior and interior sheathing; with said method of making a prefabricated stud panel comprising the steps of: a) building a frame comprising the first and second plates, the outer studs, and the inner studs; b) engaging one of the exterior and interior sheathing on a first face of said frame such that a second face of the frame is an open face; c) introducing cellular polymer insulation into the frame via the open face of the frame such that cellular polymer insulation is introduced into at least one inner region; and then d) engaging the other of the exterior and interior sheathing on the second face of the frame to close off the open face and form the prefabricated stud panel; and e) with at least one of the inner studs having a width less than a width between the inner faces of the exterior and interior sheathing such that a space is provided between said inner stud and one of the exterior and interior sheathing, and further comprising the step of introducing said cellular polymer insulation into the space such that cellular polymer insulation in one inner region communicates with cellular polymer insulation in an adjacent inner region and such that a thermal break is provided via said inner stud extending incompletely between the exterior and interior sheathing.