Abstract:
Wall systems and methods for making such wall systems are disclosed herein. According to one embodiment, a wall system comprises a plurality of vertically displaced horizontal support members, and a wall panel having at least one inwardly-extending ridge. The wall system also includes at least two foam insulation blocks. Each block has a surface that is adapted to conform to the shape of the inwardly-extending ridge of the wall panel. The blocks are spaced apart along each of the horizontal support members and are fastened between the panel and the support member. The spacing created by the blocks allows for a blanket of insulation between the blocks and the support members to expand, improving the system&#39;s insulative properties.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. patent application Ser. No. 13/416,959, filed Mar. 9, 2012, which claims priority to U.S. Provisional Application No. 61/451,056 filed Mar. 9, 2011, the disclosures of which are herein incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The invention relates generally to the field of constructing buildings. More specifically, the invention relates to the field of insulating metal buildings. 
         [0004]    2. Description of the Related Art 
         [0005]    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. 
         [0006]    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. 
         [0007]    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 packed-down insulation create heat losses. 
       SUMMARY 
       [0008]    The disclosed embodiments include a wall system that is adapted to be installed onto vertically displaced horizontal support members (e.g., girts) on a building. In one embodiment, the system comprises a wall panel having at least one inwardly-extending feature (e.g., a ridge or channel). In embodiments, a number of foam insulation blocks are adapted (on one side) to conform to the shape of the inwardly-extending feature. Further, the blocks can be spaced apart (vertically) along each of the horizontal support members, and then fastened between the wall panel and the support members. The blocks are also spaced apart horizontally which creates an array. The thickness of the blocks creates a gap. The gap allows a blanket of insulation to be expanded into space created between the blocks. 
         [0009]    In one embodiment, each of the blocks in the plurality has forwardly angled opposing sides which conform to a reciprocal shape of the feature (e.g., a ridge) and a backside that is adapted to be fixed to an outer flange on each girt. 
         [0010]    A method is also disclosed which involves (i) providing a building structure having a plurality of vertically displaced horizontal support members; (ii) obtaining a wall panel having at least one inwardly-extending feature on an inside surface of the wall; (iii) conforming the shape of one side of each of a plurality of insulating blocks to the inwardly extending feature; (iv) placing the plurality of foam insulation blocks between an outside of the horizontal support members and the inwardly-extending feature; and (v)fastening the wall to the horizontal support members, thus sandwiching the blocks. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0011]    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: 
           [0012]      FIG. 1A  shows a cross-sectional wall section of a conventional insulated wall panel. 
           [0013]      FIG. 1B  shows a top view of a horizontal section taken from a conventional insulated metal building wall design. 
           [0014]      FIG. 1C  is a broken out section showing the specifics around a girt for the conventional design shown in  FIGS. 1A and 1B . 
           [0015]      FIG. 1D  shows a conventional wall which could be used to accomplish the objectives of the disclosed embodiments. 
           [0016]      FIG. 2  shows a perspective view of an insulated wall according to the invention disclosed herein. 
           [0017]      FIGS. 3A ,  3 C, and  3 D show an angle-edged spacer block from perspective, above, and in front, respectively. 
           [0018]      FIG. 4A  shows a vertical section taken from the insulated wall of the present invention. 
           [0019]      FIG. 4B  shows a horizontal section taken of the insulated wall of the present invention. 
           [0020]      FIG. 4C  shows a broken out section taken from the vertical section of  FIG. 4A . 
           [0021]      FIG. 4D  shows a broken out section taken from the horizontal section taken from  FIG. 4B . 
       
    
    
     DETAILED DESCRIPTION 
       [0022]    Embodiments of the present invention provide an insulated metal panel system for a building, and a method for constructing a metal panel for the wall of a building. 
         [0023]    In order to provide a context for the disclosed embodiments, prior art drawings  FIG. 1A ,  FIG. 1B , and  FIG. 1C  show that which is known in the prior art. Referring first to  FIG. 1A , a conventional system  10  is shown in which a metal wall panel  12  is installed to create a building wall. This sort of wall panel  12  is normally fastened to a plurality of horizontally running and vertically spaced Z-girts  14 . The metal wall panel  12  is typically fastened to the horizontal Z-girt using fasteners  16 , which are typically self-tapping screws. 
         [0024]    When insulation is desired, a blanket of insulation  18  having a facing  19  on the inside is typically unrolled, draped down the wall, and then secured between the wall panel  12  and the Z-girts  14  using fasteners  16 . The fasteners  16  are screwed into the outer flange  24  of the girt, as shown in  FIG. 1C . The facing  19  prevents undesirable contact with inhabitants, presents a more appealing look, and creates a vapor barrier. When installed, the insulation is pinched between the inside surface of the vertical channels  22 . The vertical channels  22 , which run up and down the wall  12 , are the innermost part, meaning that they extend towards the building interior the furthest (See  FIG. 1B ). Between each of these channels, an outermost raised portion  20  of the wall  12  also extends uniformly in a vertical direction. It is through the channel area  22  of the wall  12  that the fasteners  16  are driven, then through the insulation blanket  18 , then into the girt outer flange  24 . 
         [0025]    Looking at the exploded view in  FIG. 1C , it can be seen that when the fastener  16  is screwed through the inner portion  22  of the wall it presses against the outermost flange  24  of the girt  14  sandwiching a portion  26  of the insulation. 
         [0026]    The compacting of insulation  18  in area  26  causes significant heat losses. As those skilled in the art will recognize, the mashing down of blanket creates an area where the thermal resistance is weakened. Because of this, if one were to look at heat flow diagrams in the areas near the outer flange of the girt, they would see significant flow of heat energy through the area surrounding the fastener  16 , with the heat losses being reduced at the locations spaced above or below the girt outer flanges. This is because the insulation  18  (e.g., half way between the girts in  FIG. 1A ) billows and fluffs outward the further it is from the sandwiching girt outer flanges  24 . And considering that the insulation blanket is pinned between the inside surface of the channel  22  and the girt outer flange  24  at numerous locations in the panel  112 , the heat loss resulting would appear as a plurality of vertically displaced parallel horizontal stripes of heat loss on the outside of each so-configured wall of the building. 
         [0027]    The arrangement of the present invention  110  which can be seen in  FIGS. 2 through 4  greatly reduces the heat losses in the metal wall  112 . As with the conventional system, the metal wall  112  is attached outside of the girts  114  of the building using fasteners  116 . Also like with the conventional systems a blanket of faced insulation  118  is draped down, and installed between the wall and the girt  114  when the wall is mounted. Also like with the conventional systems, the insulation blanket has a facing  119  on the inside of the insulation. Further, the new system  110 , like conventional system  10 , is fastened at the innermost channel portions  122  of the wall  112 . 
         [0028]    But the new system  110  is different in that the outer flanges of the girt  124 , upon fastening of the wall panel  112 , are not directly pressed against the blanket insulation  118 . Instead, a plurality of foam spacer blocks  126 , each having forwardly angled opposing sides, are intermittently fastened between the wall  112  and girt outer flange  124  along the length of the girt  14 . 
         [0029]    As can be seen in  FIG. 4A , spacer blocks  126  are spaced vertically by a considerable distance  128 . Distance  128  is far greater than the lengthwise dimension of each block allowing for significant vertical spacing between blocks. Also, laterally, the spacer blocks  126  (as can be seen in  FIG. 4B ) are laterally spaced a distance  130 . This creates significant thermodynamic advantages in that the spacer blocks  126 , since they are constructed of insulating foam, thermodynamically isolate and displace the metal wall panel  112  from the girt. The lateral dimension of each block is significantly less than the horizontal distance  130  between the blocks, this distance  130  being dictated by the distance between the ridges/channels  122  on the wall panel  112 . See  FIG. 2 . Further, the blanket insulation  118  is only pinched against the girt outer flanges  124  in a few spread-apart locations. Thus, the blocks  126 , in addition to providing thermal resistance, also serve to space the wall apart from the girt outer flange. This creates more area for the blanket insulation to billow out (fluff) into, and also prevents the heat loss from extending nearly the full distance of the girt outer flange, as happens in the conventional designs like that shown in  FIGS. 1A-C . 
         [0030]    Details of the spacer block  126  can best be seen in  FIGS. 3A-D . Referring first to  FIG. 3A , it can be seen that each spacer block  126  has a front face  302  (see  FIG. 3C ) and two opposing angled front faces  304 . Laterally, spacer block  126  has sides  306  which extend back to two rear portions  308  which are created by truncating the back portions of the block at converging angles, and then a rear face  310 .  FIG. 3D  shows the back of the block  126 . A top  312  of the block  126  can be seen in  FIG. 3B  and is pointed to in both of  FIGS. 3C and 3D . Although it is not shown, the bottom of block  126  is the same as the top  312 , and the block  126  is symmetrical from side to side, and top to bottom. 
         [0031]    As can best be seen in FIGS.  2  and  4 C-D, these blocks  126  are specially configured to fit inside between the inside ridge surfaces of the channel/ridge portions  122  of the wall and the girt outer flange  124 . More specifically, face  302  will butt against the ridge of the channel  122 , and the angled sides  304  will correspond to the sloped surfaces of the channel  122  so that the block fit inside the wall is true. On the other side of the block  126 , the back  310  will butt against the girt outer flange  124  when the wall is fastened. 
         [0032]    Each of the blocks  126  has a thickness dimension (between faces  302  and  310 ). Because of this, the placement of the blocks (in the array shown in  FIG. 2 ) results in a gap between innermost portions of the wall (e.g., the ridges) and the outer flanges  124  of the horizontal support members  114 . This enables the expansion of the blanket of insulation into the gap created. 
         [0033]    In terms of assembly in the erection of the building, the 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 insulation  118  will be draped over the outsides of the girts  114 . It is not necessary to independently fasten the insulation  118  at this point, but in may instances it will make sense to secure the blanket  118  from above and allow it to drape down before fastening the wall onto the girts  114 . The next step, in embodiments, involves the securement of the blocks in some way. In some embodiments, this would mean that the blocks would be adhered or in some other way fastened to the inside surfaces (ridges) of the wall in the positions shown before the wall is fastened in place. The precise position for adhering each block  126  will be determined by spacing the horizontal rows of blocks  126  at the vertical positions of each horizontally extending girt (see  FIG. 2 ). This enables the user with all of the blocks  126  adhered, to place the panel  112  over the draped insulation  118  and hold the panel  112  in place. Then, each fastener  116  (e.g., self-tapping screw) can be screwed through the panel  112  outside of where each block  126  exists, through the block, and bite into the girt outer flange  124 . Once all of the fasteners  116  have been installed, the panel/block assembly will be secured to the building, but significant open space will be created by the distance between the panel  112  and the girt  114 . The blocks  126  create this space. This space created not only allows for more fluffing of the insulation  118  between the girts  114 , but also allows for the fluffing into the spaces created between the blocks along the girt flange. 
         [0034]    Fluffed blanket insulation is considerably more effective as a heat barrier than insulation that is matted down. Thus, a much higher percentage of the wall panel  112  is backed by insulation which is billowed rather than matted down. Therefore, as opposed to the conventional system shown in  FIG. 1 , heat losses are greatly reduced by use of the blocks. Also, in the  FIGS. 2-4  embodiments where there is no fluffed insulation behind the wall, the foam insulation blocks  126  exist. Thus, a high level of heat resistance is provided across the whole panel after it is installed, unlike the conventional systems. 
         [0035]    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. 
         [0036]    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.