Patent Publication Number: US-2007113506-A1

Title: Thermally insulated stud and methods for producing the same

Description:
TECHNICAL FIELD  
      The present invention relates to construction materials, and more particularly, to an insulated stud and methods for producing the insulated stud.  
     BACKGROUND OF THE INVENTION  
      A typical structural member used in construction is a single length of wood as grown in the forest that has been trimmed to the desired dimensions. While such structural members have served for centuries in the construction of homes and other buildings, today&#39;s greater demand for heating and cooling efficiency has affected the choice of building materials. Materials having high thermal insulation values are currently being used in construction walls and roofs, but the search for other substitutes is continual.  
      One area which has not been affected much by this search for thermal efficiency is that of studs that are used as structural members that vertically support entire building structures. Some new laminated studs made from recycled or waste forestry products and modern glues and adhesives are used, but they are expensive and heavy. It is still desirable to have a thermally-insulated stud which is light and yet equal in strength to a wood stud.  
     SUMMARY OF THE INVENTION  
      According to one aspect, the invention is an elongated stud for supporting a vertical load.  
      The elongated stud includes a first elongated structural member having a vertical longitudinal axis and a second elongated structural member having a vertical longitudinal axis that is parallel to the vertical longitudinal axis of the first elongated structural member. The first and second elongated structural members are separated from each other and define a space therebetween.  
      A thermally insulative member fills the space between the first and second elongated structural members. The thermally insulative member provides thermal insulation against heat flow in a horizontal direction.  
      According to a second aspect, the invention is a method for making an elongated stud for supporting a vertical load.  
      The method includes the steps of: a) forming a first elongated structural member having a vertical longitudinal axis; b) forming a second elongated structural member having a vertical longitudinal axis; and c) placing the first and second elongated structural members so that their vertical longitudinal axes are parallel and there is a space defined therebetween. The method also includes the step of d) filling the space between the first and second elongated structural members with a thermally insulative material thereby forming a thermally insulative member that provides thermal insulation against heat flow therethrough in a horizontal direction.  
      According to a third aspect, the invention is an apparatus for making an elongated stud for supporting a vertical load.  
      The apparatus includes means for forming a first elongated structural member having a vertical longitudinal axis, means for forming a second elongated structural member having a vertical longitudinal axis, and means for placing the first and second elongated structural members so that their vertical longitudinal axes are parallel and there is a space defined therebetween, and  
      means for filling the space between the first and second elongated structural members with a thermally insulative material thereby forming a thermally insulative member that provides thermal insulation against heat flow therethrough in a horizontal direction. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  is a perspective views of a first preferred embodiment of the thermally-insulative stud of the present invention.  
       FIG. 2  is a second perspective view of a first preferred embodiment of the thermally-insulative stud of the present invention.  
       FIG. 3  is a side elevation view of an end of the first preferred embodiment of the thermally-insulative stud of the present invention.  
       FIG. 4  is a side elevation view of the opposite side of the first preferred embodiment of the thermally-insulative stud of the present invention.  
       FIG. 5  is a top view of an end of the first preferred embodiment of the thermally-insulative stud of the present invention.  
       FIG. 6  is a bottom view of an end of the first preferred embodiment of the thermally-insulative stud of the present invention.  
       FIG. 7  is a front view of the first preferred embodiment of the thermally-insulative stud of the present invention.  
       FIG. 8  is a back view of the first preferred embodiment of the thermally-insulative stud of the present invention.  
       FIG. 9  is a perspective view of an end of a second preferred embodiment of the thermally-insulative member of the present invention.  
       FIG. 10  is a perspective view of an end of a third preferred embodiment of the thermally-insulative member of the present invention.  
       FIG. 11  is a perspective view of a fourth preferred embodiment of the thermally-insulative member of the present invention.  
       FIG. 12  is a perspective view of a fifth preferred embodiment of the thermally-insulative member of the present invention.  
       FIG. 13  is a perspective view of a sixth preferred embodiment of the thermally-insulative member of the present invention.  
       FIG. 14  is a perspective view of a seventh preferred embodiment of the thermally-insulative member of the present invention.  
       FIG. 15  is a perspective view of an eighth preferred embodiment of the thermally-insulative member of the present invention.  
       FIG. 16  is a perspective view of a ninth preferred embodiment of the thermally-insulative member of the present invention.  
       FIG. 17  is a perspective view of a tenth preferred embodiment of the thermally-insulative member of the present invention.  
       FIG. 18  is a perspective view of an eleventh embodiment of the thermally-insulative member of the present invention.  
       FIG. 19  is a perspective view of a twelfth embodiment of the thermally-insulative member of the present invention.  
       FIG. 20  is a perspective view of a thirteenth embodiment of the thermally-insulative member  40 ′ of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION  
       FIGS. 1 and 2  are perspective views of a first preferred embodiment of the thermally-insulative stud of the present invention.  FIG. 3  is a side elevation view of an end of the first preferred embodiment of the thermally-insulative stud of the present invention, and  FIG. 4  is a side elevation view of the opposite side of the first preferred embodiment of the thermally-insulative stud of the present invention.  FIG. 5  is a top view of an end of the first preferred embodiment of the thermally-insulative stud of the present invention, and  FIG. 6  is a bottom view of an end of the first preferred embodiment of the thermally-insulative stud of the present invention.  FIG. 7  is a front view of the first preferred embodiment of the thermally-insulative stud of the present invention and  FIG. 8  is a back view of the first preferred embodiment of the thermally-insulative stud of the present invention. The thermally-insulative stud  40  is intended primarily for supporting a downward vertical load, such as the weight borne by a stud in structure construction, although it can also support an upward vertical load.  
      The thermally insulative stud  40  includes a first elongated structural member  42 , a second elongated structural member  44 , and a thermally-insulative member  46 . The first and second elongated structural members  42  and  44  are each made from a single integral piece of material. If the material is a sheet metal, such as galvanized steel or aluminum, the first and second elongated structural members  42  and  44  are formed by properly bending the sheet. A  16  gauge sheet metal has been found suitable for many applications, although other gauges can be chosen as desired. If the material is a formed material, such as fiberglass or carbon fiber composites, the first and second elongated structural members  42  and  44  are shaped properly before their shape is set by some further action, such as a thermal or chemical reaction.  
      The first and second elongated structural members  42  and  44  have respective first and second axes  48  and  50 , and, in use, the first and second elongated structural members  42  and  44  are placed so that the respective first and second axes  48  and  50  are vertical. Furthermore, the first and second elongated structural members  42  and  44  are placed so that there is a space  52  therebetween. In some embodiments, the first and second elongated structural members  42  and  44  are touching, whereas in some other embodiments, the first and second elongated structural members  42  and  44  are not touching. However, the space  52  is generally limited to the volume defined between the first and second elongated structural members  42  and  44 .  
      The thermally-insulative member  46  is formed or placed in the space  52  and in contact with the first and second elongated structural members  42  and  44 . The placement is set so that the first and second elongated structural members  42  and  44  each extend horizontally toward one another and relative to the thermally-insulative member  46 . The thermally-insulative member  46  is formed from any material having a suitable thermal insulation value. Preformed blocks made from expanded or extruded polystyrene are suitable, although polyethylene polyisocyhalrite and polyurethane are also suitable plastics. Other insulative materials such as a mixture of mud and straw are also suitable for some applications. However, it is preferable to form the thermally-insulative member  46  within the space  52  so that it adheres to the interior surfaces of the first and second elongated structural members  42  and  44 .  
      In the first preferred embodiment shown in  FIGS. 1-8 , the first and second elongated structural members  42  and  44  are channels, formed by bending a length of galvanized sheet steel along two parallel lines to form edges  54 . The first elongated structural member  42  includes a web  56  that extends between a first leg  58  and a second leg  60 . Similarly, the second elongated structural member  44  includes a web  62  that extends between a first leg  64  and a second leg  66 . The web  62  is parallel to the web  56 , and the first legs  58  and  64  and the second legs  60  and  66 , respectively extend toward one another. Depending upon the lengths of the first and second legs  64  and  66  relative to the web  62 , the channels can be characterized as C- or U-channels, with U-channels having first legs  58  and second legs  60  that are longer than the web  62 .  
      The thermally-insulative member  46  has a vertical dimension that is equal, or very nearly equal, to the vertical dimensions of the first and second elongated structural members  42  and  44 . The horizontal dimensions of the thermally-insulative member  46  are such that the thermally-insulative member  46  substantially fills the space between the first and second elongated structural members  44  and  46 . As a result, if the first and second elongated structural members  42  and  44  do not touch, a portion of the thermally-insulative member  46  is exposed between the two first legs  58  and  64  and between the two second legs  60  and  66 .  
      The first and second elongated structural members  42  and  44  support the load applied to the stud  40 , and the thermally-insulative member  46  substantially increases the overall thermal insulation value of the stud  40 , including in the horizontal direction. The stud  40  can be built in any desired dimensions. However, the vertical height of the stud  40  is typically 8 or more feet, while the width of the stud  40  is typically 3.5 and 5.5 inches.  
      Where the following embodiments are substantially similar to the first embodiment, their features which are the same as those of the first embodiment will be given the same reference numerals, but will be used only if necessary to describe their differences from the first embodiment.  
       FIG. 9  is a perspective view of an end of a second preferred embodiment of the thermally-insulative member of the present invention. The second preferred embodiment of the thermally-insulative stud  40  is substantially similar to the first preferred embodiment described in  FIGS. 1-8 , except that the second elongated structural member  44  is turned 180 degrees about its vertical axis  50  as compared to the embodiment in  FIGS. 1-8 . The first elongated structural member  42  has an aperture  68 , as is conventional with metal studs. The space  52  is defined between the first and second elongated structural members  42  and  44 , and is substantially filled with a thermally-insulative member  46  (not shown).  
       FIG. 10  is a perspective view of an end of a third preferred embodiment of the thermally-insulative member of the present invention. The third preferred embodiment is made from two separated C-channels which serve as the first and second elongated structural members  42  and  44  and whose legs are directed to the legs of the other C-channel. The space  52  between the first and second elongated structural members  42  and  44  is substantially filled with a thermally-insulative member  46  (not shown).  
       FIG. 11  is a perspective view of a fourth preferred embodiment of the thermally-insulative member of the present invention. The fourth preferred embodiment of the thermally-insulative stud  40  of the present invention is substantially the same as the first preferred embodiment of the thermally-insulative stud  40  shown in  FIGS. 1-8 . However, the fourth preferred embodiment shows the first and second elongated structural members  42  and  44  with their respective first legs  58  and  64  and second legs  60  and  66  directed away from one another. The space  52  between the first and second elongated structural members  42  and  44  is substantially filled with a thermally-insulative member  46  (not shown).  
       FIG. 12  is a perspective view of a fifth preferred embodiment of the thermally-insulative member of the present invention. The fifth preferred embodiment of the thermally-insulative stud  40  of the present invention is substantially the same as the first preferred embodiment of the thermally-insulative stud  40  shown in  FIGS. 1-8 . However, the two C-channels (elongated structural members  42  and  44 ) are touching along the seams  80 , which may be stitch welded or otherwise connected to hold the first and second elongated structural members  42  and  44  together as a unit. The first and second elongated structural members  42  and  44  define the space  52 , which is substantially filled with a thermally insulative member  46  (not shown).  
      In addition, a sheet of material  82  can be attached to one of the faces of the combined first and second elongated structural elements  42  and  44  (such as that composed of the first legs  58  and  64 , the second legs  60  and  66 , the web  56  or the web  62 ). The sheet of material  82  could be insulative, structural, fireproofing, or decorative. For example, the sheet of material  82  could be made from ⅛″ cement board or a veneer, or even from a paintable or otherwise appliable coating, as will be known by those skilled in the relevant arts. The sheet of material  82  can be applied to any of the preferred embodiments of the thermally-insulative member of the present invention that are disclosed in the foregoing or following detailed descriptions, or to any equivalents that would be known by those skilled in the relevant arts.  
       FIG. 13  is a perspective view of a sixth preferred embodiment of the thermally-insulative member of the present invention. In this embodiment, the first elongated structural member  42  is an elongated rectangular sheet of material and the second elongated structural member  44  is an elongated U-channel. Alternatively, the first elongated structural member  42  can be connected to the second elongated structural member  46  by means such as conventional fasteners or stitch welding. The first and second elongated structural members  42  and  44  define the space  52 , which is substantially filled with a thermally insulative member  46  (not shown).  
       FIG. 14  is a perspective view of a seventh preferred embodiment of the thermally-insulative member of the present invention. In this embodiment, the first elongated structural member  42  is an elongated rectangular sheet of material and the second elongated structural member  44  is an elongated C-channel. Alternatively, the first elongated structural member  42  can be connected to the second elongated structural member  46  by means such as conventional fasteners or stitch welding. The first and second elongated structural members  42  and  44  define the space  52 , which is substantially filled with a thermally insulative member  46  (not shown).  
       FIG. 15  is a perspective view of an eighth preferred embodiment of the thermally-insulative member of the present invention. The first elongated structural member  42  is an elongated channel (either a C-channel or a U-channel, or other known variants) and the second elongated structural member  44  is a box member (either square or rectangular cross-section, or other known variants). The first and second legs  58  and  60  are directed toward and either spaced apart from, or contacting, the second elongated structural member  44 . The first and second elongated structural members  42  and  44  define the space  52 , which is substantially filled with a thermally insulative member  46  (not shown).  
       FIG. 16  is a perspective view of a ninth preferred embodiment of the thermally-insulative member of the present invention. The ninth embodiment is similar to the sixth preferred embodiment shown in  FIG. 13 , except that the first elongated structural member  42  is a C-channel with relatively short first and second legs  58  and  60 . The first and second elongated structural members  42  and  44  define the space  52 , which is substantially filled with a thermally insulative member  46  (not shown).  
       FIG. 17  is a perspective view of a tenth preferred embodiment of the thermally-insulative member of the present invention. The tenth embodiment is similar to the ninth preferred embodiment shown in  FIG. 16 , except that the second elongated structural member  44  is a C-channel with relatively short first and second legs  64  and  66 . The first and second elongated structural members  42  and  44  define the space  52 , which is substantially filled with a thermally insulative member  46  (not shown).  
       FIG. 18  is a perspective view of an eleventh embodiment of the thermally-insulative member of the present invention. The eleventh embodiment is similar to the tenth embodiment shown in  FIG. 17 , except that the first elongated structural member  44  engages the second elongated structural member  46  since the web  56  of the first elongated structural member  42  has a different dimension from that of the web  62  of the second elongated structural member  44 , which is also a C-channel. This allows the legs of the C-channel having the shorter web to fit between the legs of the other C-channel. The first and second elongated structural members  42  and  44  define the space  52 , which is substantially filled with a thermally insulative member  46  (not shown).  
       FIG. 19  is a perspective view of a twelfth embodiment of the thermally-insulative member of the present invention. The first and second elongated structural members  42  and  44  are conventional C-channel metal studs having respective webs  56  and  62 . The first elongated structural member  42  also has first and second legs  58  and  60 . However, the first leg  58  has an attached flange  90  which is substantially parallel to the web  56  and directed toward the second leg  60 , but is substantially shorter than the web  56 . Similarly, the second leg  60  has an attached flange  92  which is substantially parallel to the web  56  and directed toward the first leg  58 , but is substantially shorter than the web  56 . The second elongated structural member  44  is substantially identical to the first elongated structural member  42 . It has respective flanges  94  and  96  that are attached to respective legs  66  and  64 . The twelfth embodiment of the thermally-insulative member of the present invention is formed by placing the first and second elongated structural members  42  and  44  in contact, with respective flanges  90  and  96  of the first and second elongated structural members  42  and  44  aligned and in contact and with respective flanges  92  and  94  of the first and second elongated structural members  42  and  44  aligned and in contact. If desired, the flanges of the first and second elongated structural members  42  and  44  can be held together by fasteners or welding. The first and second elongated structural members  42  and  44  define the space  52 , which is substantially filled with a thermally insulative member  46  (not shown).  
       FIG. 20  is a perspective view of a thirteenth embodiment of the thermally-insulative member  40 ′ of the present invention. The first elongated structural member  42 ′ is a conventional C-channel metal stud as described above in the description of  FIG. 19 . The second elongated structural member  44 ′ is the structure  40  described in  FIG. 19 . The flanges  90 ′ and  92 ′ of the first elongated structural member  42 ′ are attached to the web  56  of the second elongated structural member  44 ′. The first and second elongated structural members  42 ′ and  44 ′ define the space  52 , which can be substantially filled with a thermally insulative member  46  (not shown). Alternatively, the space  52 ′ of the second elongated structural member  44 ′ can be substantially filled with a thermally insulative member  46  (not shown). As a further alternative, both of the spaces  52  and  52 ′ can be filled with a thermally insulative member  46  (not shown).  
      While the foregoing is a detailed description of the preferred embodiment of the invention, there are many alternative embodiments of the invention that would occur to those skilled in the art and which are within the scope of the present invention. In particular, the elongated structural members described in this application are an important, but small, part of those known to those skilled in the relevant arts. Further, the insulative materials and their manners of application that are described in this application are an important, but small, part of those known to those skilled in the relevant arts. Both the elongated structural members and the insulative materials and their manners of application described in this application are only illustrative. Accordingly, the present invention is to be determined by the following claims.