Abstract:
Disclosed is a wall system and a method of fabricating that wall. The system uses a stanchion, or bracket. The bracket is installed between the outer flanges of the structural girts that make up the wall and a wall panel. The tabs create space between the girt and panel that enables insulation to be spread out into the additional space created. This reduces heat losses in the wall.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 61/472,400 filed Apr. 6, 2011, the entire contents of which are herein incorporated by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention relates generally to the field of constructing buildings. More specifically, the invention relates to the field of fabricating insulated metal walls for metal buildings. 
     2. Description of the Related Art 
     Conventionally, metal buildings are constructed according to a series of steps. First, a metal frame is constructed. The metal frame includes numerous structural support members. The roof portions include sloped roof structural members referred to as purlins. The walls include vertically spaced horizontally extending members, which are referred to as girts. Once the frame is installed, it is common to insulate both the roof and wall portions of the building. 
     With respect to roof arrangements, blanket insulation is draped over the tops of the purlins, and then roof panels are fastened over the insulation. In some cases, it has been known to install a longitudinal thermal block above the top flange of the purlin such that it runs the entire length of the purlin over the draped blanket insulation. 
     With respect to the conventional wall, blanket insulation is secured from above such that it is draped over horizontally extending girts. Then metal wall panels are fastened to the outer flanges of the girts, mashing the blanket insulation between the wall panel and the outer flange of each girt where they interface. These lines of mashed down insulation create heat losses. 
     SUMMARY 
     In embodiments, the invention is a wall system that is structurally supported by vertically displaced horizontal support members (e.g., girts). In embodiments, the system includes a wall panel of the kind having inwardly-extending channels. In a first embodiment a bracket is installed between the girts and wall panel. Each bracket has a plurality of tabs. The tabs are spaced apart from one another on the bracket, and extend laterally outward. Portions of each tab are configured to secure the bracket between the wall panel and the vertically displaced horizontal support member. In a second alternative embodiment, independent tabs (not on a bracket) can be spaced apart along each of the horizontal support members. Regardless, space is created between the outer flanges of the girts and inwardly-extending channels on the wall panel. This space allows a blanket of insulation to be expanded into space created between the tabs. 
     A method for fabricating a wall is also disclosed. The method includes (i) providing a plurality of vertically spaced, horizontally extending structural members, (ii) draping insulation outside of the horizontally extending structural members, (iii) fastening connector portions on laterally extending tabs on a plurality of bracket members over the blanket insulation into a plurality of outer flanges of each of the plurality of horizontally extending structural members, and (iv) installing a wall panel outside of the insulation by fastening the wall panel to an outer flange on the bracket. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       Illustrative embodiments of the present invention are described in detail below with reference to the attached drawing figures, which are incorporated by reference herein and wherein: 
         FIG. 1A  shows a cross-sectional wall section of a conventional insulated panel; 
         FIG. 1B  shows a top view of a horizontal section taken from a conventional insulated metal building wall design; 
         FIG. 1C  is a broken out section showing the specifics around a girt for the conventional design shown in  FIGS. 1A and 1B ; 
         FIG. 1D  is a perspective view of an exemplary wall panel; 
         FIG. 2  shows a perspective view of an insulated wall according to the invention disclosed herein; 
         FIG. 3A  is a perspective view of a stanchion bracket in line with the teachings of the present invention; 
         FIG. 3B  shows a flat metallic piece that can be machined to make the stanchion bracket of  FIG. 3A ; 
         FIG. 3C  shows an end view of the stanchion bracket of  FIG. 3A ; 
         FIG. 4A  shows a vertical section taken from the insulated wall of the present invention; 
         FIG. 4B  shows a horizontal section taken from the insulated wall of the present invention; 
         FIG. 4C  shows a broken out section taken from the vertical section of  FIG. 4A ; 
         FIG. 4D  shows a broken out section taken from the horizontal section taken from  FIG. 4B ; 
         FIG. 5A  shows a perspective view of a spacer tab in line with the teachings of the present invention; and 
         FIG. 5B  shows an end view of the spacer tab of  FIG. 5A . 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments of the present invention provide an insulated metal panel system for insulating a building. To provide context for the disclosed embodiments, consider  FIGS. 1A, 1B, 1C, and 1D  which show the current state of the art. 
       FIG. 1A  shows a conventional system  10  wherein a metal wall panel  12  is installed to create a building wall. The type of paneling shown in  FIGS. 1A-D  is referred to by the trade name SHADOWALL® and is manufactured by BlueScope Butler located in Kansas City, Mo., a business group of BlueScope Steel Limited, Australia. As shown in  FIG. 1D , the wall panel  12  may include vertical channels (or ridges)  22  that run up and down the panel  12 . These vertical channels  22  constitute the inner most part of the panel  12 , i.e., these channels  22  extend towards the building interior the furthest (see  FIG. 1B ). Between each of these vertical channels  22  a subtle V-dip  20  also extends in the same direction as the channels (ridges)  22  (see  FIG. 1D ). 
     As shown in  FIG. 1A , this type of metal panel  12  is commonly fastened to a plurality of horizontally running and vertically spaced Z-girts  14 . Each Z-girt  14  has an outer flange  24  (see  FIG. 1C ) to which, using fasteners  16 , the metal wall panel  12  is fastened. The fasteners  16  typically are self-tapping screws. 
     When it is desirable to insulate the wall, a blanket of insulation  18  may be unrolled and draped down the wall panel  12  before the panel  12  is secured to the Z-girts  14 . The blanket of insulation  18  may have a facing  19  on the inside, which prevents contact with inhabitants, presents a more appealing look, and creates a vapor barrier. The draping process may involve tacking the blanket  18  in some manner to the uppermost purlin so that it remains in an unfurled position. After being unrolled and draped down the panel  12 , the blanket of insulation  18  is secured between the wall panel  12  and the outer flanges  24  of the plurality of Z-girts  14  using the fasteners  16  (see  FIG. 1A ). More specifically, the fasteners  16  are driven through the vertical channels  22 , the blanket of insulation  18 , and then into the outer flanges  24  of the Z-girts  14 . 
     When a fastener  16  is screwed through the inner most portion (channel  22 ) of the wall, it presses against the outer flange  24  of the corresponding Z-girt  14 , and sandwiches a portion  26  of the blanket of insulation  18  (see  FIG. 1C ). This compacting of the blanket of insulation  18  creates an area where the thermal resistance is weakened, which allows for considerable heat losses. If one were to look at the heat flow diagrams in the area near the flange  24  of Z-girt  14 , one would see significant flow of heat energy through the area surrounding the fastener  16 . Conversely, one would note that the heat losses are reduced at locations spaced above or below the flanges  24  of the Z-girts  14 . This reduction in heat loss at the inter-girt positions is because the blanket of insulation  18  (for example, halfway between the vertically spaced Z-girts  14  in  FIG. 1A ) billows and fluffs outward the further it is from the girt flanges  24 , allowing for more air, which is a good insulator of heat, to aid in the insulation. As the blanket of insulation  18  is pinned between the inside surface of the channels  22  and the girt flange  24  at numerous locations in the panel  12 , the resulting heat loss would appear as a plurality of vertically displaced parallel horizontal stripes on the outside of each wall of the building so configured. 
     The arrangement disclosed by the current invention  110 , which can be seen in  FIGS. 2 through 5 , greatly reduces heat losses in a metal wall  112  (see  FIG. 2 ). As with the conventional system  10 , the metal wall  112  is attached outside Z-girts  114  of the building using fasteners. Also, like the conventional system  10 , when the wall  112  is mounted, a blanket of insulation  118  having a facing  119  is draped down and installed between the wall  112  and the Z-girt  114 . Further, akin to the conventional system  10 , the new system  112  is fastened at innermost channel portions  122  of the wall  112  (see  FIG. 2 ). 
     But the new system  110  is different from the conventional system in that the blanket of insulation  118 , upon securing the metal wall panel  112 , is not directly pressed and sandwiched between the metal wall panel  112  and the flange  124  of the Z-girt  114 . Instead, a laterally extending stanchion bracket  132  (see  FIG. 2 ) is installed over the insulation  118  and is fastened between the wall panel  112  and outer flange  124  of the Z-girt  114  along the length of the girt  114 . 
     The stanchion bracket  132 , as shown more clearly in  FIG. 3A , comprises a laterally extending support bar  134  and plurality of tabs  126  spaced along the length of the support bar  134 . Each tab  126  has an outwardly extending portion  126   a  which extends outward from the support bar  134  and terminates at an edge  126   b . The edge  126   b  of the outwardly extending portion  126   a  constitutes that part of the outwardly extending portion  126   a  which is furthest away from the support bar  134 . Each tab  126  further comprises a downwardly extending portion  126   c  that extends downward from the edge  126   b.    
     The stanchion bracket  132  may be constructed from a flat metallic piece  131  (see  FIG. 3B ) that is configured, by known methods, to form the finished stanchion bracket  132 . Some or all of the tabs  126 , within their downwardly extending portions  126   c , may include openings or holes  126   h . The support bar  134  may also have holes  132   h  that are laterally spaced along the support bar  134  at a distance  1321 , which distance  1321  generally corresponds to a lateral distance between two vertically extending adjacent channels  22  (see measurement  221  in  FIG. 1D ). 
     In terms of assembly in the erection of the building, the Z-girts  114  will already be in place as shown in the figures, and the remaining wall components will be installed outside them. In some embodiments, the blanket of insulation  118  will be draped over the outside of flanges  124  of the Z-girts  114 . It is not necessary to independently fasten the insulation  118  at this point, but in many instances, it will make sense to secure the blanket  118  from above and allow it to drape down outside the girt flanges  124  before securing the wall panel  112  to the Z-girts  114 . 
     The next step, in embodiments, involves securing the stanchion brackets  132 . In some embodiments, this would mean that the tabs  126  of the stanchion bracket  132  are secured to the flange  124  of the Z-girt  114  on top of the insulation  118  before the wall panel  112  is secured to the support bar  134  of the bracket  132 . After the tabs  126  are aligned and fixed such that they extend along the length of the Z-girt  114 , fasteners  116  (see  FIG. 4C ) are passed through the holes  126   h  in the tabs  126  and the blanket of insulation  118 , and made to bite into the flange  124  of the Z-girt  114 . The portions of insulation trapped underneath the tabs  126  of the stanchion  132  are relatively small, and after they are secured to the girt flange  124 , the surrounding insulation easily puffs outward to fill all the areas surrounding the tabs  126 . Care may be taken to horizontally align the tabs  126  along the flange  124  in such a way that at least one channel  122  of the panel  112 , when the panel  112  is subsequently installed, corresponds to a hole  132   h  in the support bar  134  of the bracket  132 . 
     The next step, after the tabs  126  are secured to the flange  124  via fasteners  116 , is to stand the panel  112  upright such one or more channel portions  122  of the panel  112  align with the hole  132   h  in the support bar  134  of the bracket  132 . Specifically, fasteners  133  (see  FIG. 4C ) are passed through the channel  122  from the outside, and then passed through hole  132   h  in the support bar  134 . The panel  112 , thereby, is indirectly secured to the flange  124  of the Z-girt  114 . 
     Because the outwardly extending portions  126   a  of the tabs  126  displace the panel  112  from the outer flange  124  of the Z-girt  114 , significant open space is created between the girt  114  and the panel  112  so that the insulation  118  can fill the space. Moreover, each tab  126  is laterally spaced from an adjacent tab  126  by a distance  130  (see  FIG. 4B ), and a bracket  132  is vertically spaced from another bracket  132  by a considerable distance  128  (See  FIG. 4A ). These distances create more area for the blanket of insulation  118  to fluff out into, both between the vertically spaced Z-girts  114 , and also into the lateral spaces  130  between adjacent tabs  126 . Fluffed blanket insulation  118  is far more effective as a heat barrier than insulation  118  that is matted down. Thus, a much higher percentage of the wall panel  112  is backed by insulation that is billowed rather than matter down, and consequently, heat losses are greatly reduced because of the stanchion brackets  132 . 
     It is also possible to achieve the objectives stated above by using, instead of or along with the stanchion bracket  132 , a plurality of independent tabs  200   a  (see  FIGS. 5 and 5B ) that are laterally spaced along the length of the outer flange  124  of the Z-girt  114 . In this embodiment, the tab  200   a  has a base member  202   a  having edges  204   a  and  206   a . A connector portion  208   a  having an opening or hole  208   h  extends vertically upward from the edge  204   a , whereas a connector portion  210   a  having an opening or hole  210   h  extends vertically downward from the edge  206   a . The tabs  200   a  are first secured to the flange  124  of the Z-girt  114  over the insulation  118  by a fastener that extends through the hole  210   h  in the connector portion  210   a , and then bites into the flange  124  of the Z-girt  114 . As before, in terms of horizontal placement of the tabs  200   a  along the flange  124 , care may taken that the tabs  200   a  are secured to the flange  124  in such a way that the holes  208   h  in the connector portion  208   a  correspond with channel portions  122 . After the tabs  200   a  are secured to the flange  124 , the panel  112  may be stood upright and secured to the connector portions  208   a  of the tabs  200   a;  specifically, a fastener may be passed, from the outside of the channel  122 , through the channel  122  and the hole  208   h  of the connector  204   a , thereby indirectly securing the panel  112  to the flange  124  of the Z-girt  114 . These independent tabs  200   a  may allow for greater flexibility than the stanchion bracket  132 , as any number of tabs  200   a  can be secured and spaced as desired in line the requirements of a particular project. 
     Many different arrangements of the various components depicted, as well as components not shown, are possible without departing from the spirit and scope of the present invention. Embodiments of the present invention have been described with the intent to be illustrative rather than restrictive. Alternative embodiments will become apparent to those skilled in the art that do not depart from its scope. A skilled artisan may develop alternative means of implementing the aforementioned improvements without departing from the scope of the present invention. 
     It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims. Not all steps listed in the various figures need be carried out in the specific order described.