Patent Publication Number: US-7905073-B2

Title: Method and apparatus for assembling strong, lightweight thermal panel and insulated building structure

Description:
CLAIM TO DOMESTIC PRIORITY 
     The present application is a continuation of application Ser. No. 10/875,708, filed Jun. 24, 2004, which is a continuation of application Ser. No. 10/101,549, now U.S. Pat. No. 6,796,093, filed Mar. 18, 2002. 
    
    
     This invention relates to construction. 
     More particularly, the invention relates to a method and apparatus for assembling a strong, lightweight thermal panel. 
     In a further respect, the invention relates to a method and apparatus for quickly assembling a thermally insulated building structure. 
     For many years, residential and other building structures have been constructed by erecting a frame consisting of two by fours and other wood lumber, and by mounting sheet rock and other siding and insulation on or between the two by fours. One conventional disadvantage of wood frames is that they are susceptible to termite damage. Another disadvantage is that the wood currently used to build wood frames often is relatively “young” and not fully cured, which increases the likelihood the wood will warp after it is installed and after sheet rock and other siding is mounted on the wood. A further disadvantage of wood frames is that they are, because of wood shortages, becoming increasingly expensive. Another disadvantage of wood frames is that they are labor intensive. Still a further disadvantage of wood frames is that they are hydrophilic. Still another disadvantage of wood frames is that they tend to be permeable to heat. 
     Another construction technique, commonly found in commercial buildings, is the use of metal studs to construct interior, non-load bearing walls. Such metal studs ordinarily are not utilized for exterior walls because they are excellent transmitters of heat and because they are not strong enough to be utilized to construct a load bearing wall. Like wood frames, frames constructed with metal studs also tend to be labor intensive. 
     Accordingly, it would be highly desirable to provide an improved construction system which would minimize labor, would minimize the transmission of heat into or out of a building structure, would provide load bearing walls, would simplify construction, and would resist damage by insects. 
     Therefore, it is a principal object of the invention to provide an improved construction method and apparatus. 
     Another object of the invention is to provide structural panels which can be interchangeably utilized for the roof or wall of a structure. 
     A further object of the invention is to provide a construction system which permit the exterior walls and roof of a home to be erected in a single day. 
    
    
     
       These and other, further and more specific objects and advantages of the invention will be apparent to those of skill in the art from the following detailed description thereof, taken in conjunction with the drawings, in which: 
         FIG. 1  is a perspective view illustrating the end of a metal stud constructed in accordance with the principles of the invention; 
         FIG. 2  is a side elevation view further illustrating the metal stud of  FIG. 1 ; 
         FIG. 3  is a side elevation view illustrating another metal stud constructed in accordance with the invention; 
         FIG. 3A  is a side elevation view illustrating still another metal stud constructed in accordance with the invention; 
         FIG. 4  is a section view of the metal stud of  FIG. 2  illustrating further construction details thereof; 
         FIG. 5  is a perspective view illustrating construction details of a structural panel used in the wall or roof of a building structure; 
         FIG. 6  is a perspective view illustrating construction details of a structural panel used in the wall or roof of a building structure; 
         FIG. 7  is a perspective view illustrating a side or edge of a foam panel used in the invention and illustrating the mode of operation thereof; 
         FIG. 8  is a side elevation view illustrating a building structure constructed in accordance with the invention; 
         FIG. 9  is a section view of the building structure of  FIG. 8  illustrating further construction details thereof and taken along section line  9 - 9 ; 
         FIG. 10  is a side elevation view further illustrating the roof of the building structure of  FIG. 8 ; 
         FIG. 11  is a perspective view illustrating a support member utilized in the panel construction of the type illustrated in  FIGS. 5 ,  8 ,  9 , and  10 ; 
         FIG. 12  is a front view illustrating a bracket utilized in wall construction of the type illustrated in  FIG. 8 ; 
         FIG. 13  is a side view illustrating the bracket of  FIG. 12 ; 
         FIG. 14  is a bottom view illustrating the bracket of  FIG. 12 ; 
         FIG. 15  is an enlarged side view illustrating the attachment to the floor of the wall construction of  FIG. 8 ; 
         FIG. 16  is a perspective view illustrating a roof panel construction in accordance with the invention; and, 
         FIG. 17  is a perspective view illustrating a wall panel construction in accordance with the invention. 
     
    
    
     Briefly, in accordance with the invention, I provide an improved structural panel for a building. The panel includes at least first and second stud members each comprising an elongate member. Each stud member includes a neck having a selected thickness, a front, a back, a first elongate side, a second elongate side, and a cross-sectional area; includes a plurality of openings formed through the neck intermediate the first and second elongate sides and having a cumulative cross-sectional area and a cumulative area normal to the cumulative cross-sectional area, the cumulative cross-sectional area of the openings being at least equal to the cross-sectional area of the neck; and, includes a plurality of venturi bridges each adjacent at least one of the openings and extending from the first elongate side to the second elongate side of the stud. The venturi bridges have a cumulative cross-sectional area less that the cumulative cross-sectional area of the plurality of openings; a cumulative surface area on the front of the neck; and, a cumulative surface area on the back of the neck. Each stud member also includes at least one flange outwardly projecting from one of the sides of the neck. Each of the stud members is comprised of at least one metal having a thermal conductivity greater than 0.030 g-cal/(sec.)(sq. Cm.)(degree C./cm.) at eighteen degrees Centigrade. The panel also includes a foam panel having an outside face; an inside face; a top; a bottom; a first edge having a surface area extending between the inside face and the outside face and adjacent the front of the neck of the first stud member to form a first structural and thermal transmission interface; and, a second edge having a surface area extending between the inside face and the outside face and adjacent the back of the neck of the second stud member to form a second structural and thermal transmission interface. The ratio of the surface area of the first edge to the cumulative area of the openings in the neck of the first stud is in the range of 10:1 to 1.33:1 to limit the transmission of heat from the first stud to the first edge. The ratio of the portion of the surface area of the first edge to the cumulative surface area of the venturi bridges on the front of the neck of the first stud is in the range of 25:1 to 4:1 to limit the transmission of heat from the first stud to the first edge. 
     In another embodiment of the invention, I provide an improved lightweight substantially rigid shear-resistant structural panel for a building. The panel includes at least first and second stud members each comprising an elongate member. Each stud member includes a top; a bottom; a neck having a selected thickness, a front, a back, a first elongate side, a second elongate side, and a cross-sectional area; a plurality of openings formed through the neck intermediate the first and second elongate sides and having a cumulative cross-sectional area, the cross-sectional area of the openings being at least equal to the cross-sectional area of the neck; and, a plurality of venturi bridges each adjacent at least one of the openings and extending from the first elongate side to the second elongate side of the stud. The venturi bridges have a cumulative cross-sectional area less that the cross-sectional area of the plurality of openings; a cumulative surface area on the front of the neck; and, a cumulative surface area on the back of said neck. Each stud member also includes a first flange outwardly projecting from the first elongate side of the neck; and, a second flange outwardly projecting from the second elongate side of the neck and spaced apart from and opposed to the first flange. Each of the stud members is comprised of at least one metal having a thermal conductivity greater than 0.030 g-cal/(sec.)(sq. Cm.)(degree C./cm.) at eighteen degrees Centigrade. The wall panel also includes a foam panel having an outside face; an inside face; a top; a bottom; a first edge having a surface area extending between the inside face and the outside face, adjacent the front of the first stud member to form a first structural and thermal transmission interface, and between the first and second flanges of the first stud member; and, a second edge having a surface area extending between the inside face and the outside face, adjacent the back of the second stud member to form a second structural and thermal transmission interface, and between the first and second flanges of the second stud member. The wall panel also includes a first support member extending along the top of the foam panel between the first and second stud members. The support member includes a first end connected to the top of the first stud member and a second end connected to the top of the second stud member. The wall panel also includes a second support member extending along the bottom of the foam panel between the first and second stud members. The second support member includes a first end connected to the bottom of the first stud member and a second end connected to the bottom of the second stud member. 
     In a further embodiment of the invention, I provide an improved building construction. The building construction includes a wall; and, a thermally insulated roof having a slope greater than 2/12 and including a plurality of spaced apart metal studs with thermally insulative foam panels interposed between the studs, the studs being shaped and dimensioned to engage and support the panels between the studs. 
     In still another embodiment of the invention, I provide an improved method of constructing an enclosed thermally sealed building structure. The method includes the steps of constructing a wall including a top, a plurality of spaced apart metal studs, and, a plurality of thermally insulative foam panels interposed between said metal studs; constructing a roof including a plurality of elongate metal support members, and a plurality of thermally insulative foam panels interposed between said metal support members; installing the wall at a selected construction site; and, installing the roof on the wall such that a portion of the foam panels in the roof are adjacent the top of the wall and a portion of the foam panels in the wall to form a thermal seal between the roof and the top of the wall. 
     In still a further embodiment of the invention, I provide an improved method of reducing the thermal conductivity of a structural panel for a building. The wall includes at least first and second stud members each comprising an elongate member including a neck having a selected thickness, a front, a back, a first elongate side, a second elongate side, and a cross-sectional area; and, at least one flange outwardly projecting from one of the sides of the neck. Each of the stud members is comprised of at least one metal having a thermal conductivity greater than 0.030 g-cal/(sec.)(sq. Cm.)(degree C./cm.) at eighteen degrees Centigrade. The wall also includes a foam panel having an outside face; an inside face; a top; a bottom; a first edge having a surface area extending between the inside face and the outside face and adjacent the front of the first stud member to form a first structural and thermal transmission interface; and, a second edge having a surface area extending between the inside face and the outside face and adjacent the back of the second stud member to form a second structural and thermal transmission interface. The improved method includes the steps of forming a plurality of openings through the neck of at least the first stud member intermediate the first and second elongate sides and having a cumulative cross-sectional area and a cumulative area normal to the cumulative cross-sectional area; and, forming a plurality of venturi bridges in at least the first stud member. Each venturi bridge is adjacent at least one of the openings and extends from the first elongate side to the second elongate side of the stud. The venturi bridges have a cumulative cross-sectional area less that the cumulative cross-sectional area of the plurality of openings; a cumulative surface area on the front of the neck; and, a cumulative surface area on the back of the neck. The ratio of the portion of the surface area of the first edge adjacent the cumulative surface area of the venturi bridges on the front of the neck of the first stud is in the range of 25:1 to 4:1 to limit the transmission of heat from the first stud to the portion of the first edge extending from the openings in the first stud and venturi bridges in the first stud to the inside face of the foam panel. 
     In yet still a further embodiment of the invention, I provide an improved method of producing a strong, lightweight metal stud that minimizes the transmission of heat through the stud and resists forces that act to bend the stud. The method includes the steps of providing a thin elongate metal panel having a thickness and comprised of at least one metal having a thermal conductivity greater than 0.030 g-cal/(sec.)(sq. Cm.)(degree C./cm.) at eighteen degrees Centigrade; forming a plurality of openings through the panel to produce a plurality of venturi bridges each adjacent at least one of the openings; and, bending the panel. Bending the panel forms a neck having a thickness equal to said thickness of said metal panel; a front; a back; a first elongate side; and, a second elongate side. The plurality of openings are formed through the neck intermediate the said first and second elongate sides and have a cumulative cross-sectional area and a cumulative area normal to the cumulative cross-section area. The plurality of venturi bridges each extend from the first elongate side to the second elongate side of the stud. The venturi bridges each have a cumulative cross-sectional area less that the cross-sectional area of the plurality of openings; have a cumulative surface area on the front of the neck; and, have a cumulative surface area on the back of the neck. Bending the panel also forms a first flange outwardly projecting from the first elongate side of the neck and having a thickness at least twice the thickness of the metal panel; and, forms a second flange outwardly projecting from the second elongate side of the neck, spaced apart from and opposed to the first flange, and having a thickness at least twice the thickness of the metal panel. 
     In yet still another embodiment of the invention, I provide an improved method of producing a structural panel for a building. The method includes the step of providing at least first and second stud members each comprising an elongate member. Each stud member includes a neck having a selected thickness; a front; a back; a first elongate side; and a second elongate side. Each stud member also includes at least one flange outwardly projecting from one of the sides of the neck. Each of the stud members is comprised of at least one metal having a thermal conductivity greater than 0.030 g-cal/(sec.)(sq. Cm.)(degree C./cm.) at eighteen degrees Centigrade. The method also includes the step of providing a foam panel. The foam panel has an outside face; an inside face; a top; a bottom; a first side having a surface area and having a pair of spaced apart edges; and, a second side having a surface area and having a pair of spaced apart edges. The method also includes the step of positioning the foam panel intermediate the first and second metal stud members such that a portion of the first side extends between the inside face and the outside face and adjacent the front of the first stud member to form a first structural and thermal transmission interface; such that one of the edges of the first side is adjacent the front of the first stud member; such that a portion of the first side extends away from the first stud member; such that the other of the edges of the first side is spaced apart from the first stud member; such that a portion of the second side extends between the inside face and the outside face and adjacent the back of the second stud member to form a second structural and thermal transmission interface; such that one of the edges of the second side is adjacent the back of the second stud member; such that a portion of the second side extends away from the second stud member; and, such that the other of the edges of the second side is spaced apart from the second stud member. The method also includes the steps of placing a structural member along the other of the edges of the second side; and, interconnecting the structural member and the second stud with a plurality of spaced apart support members each having a first end connected to the structural member and a second end connected to the second stud. 
     Turning now to the drawings, which depict the presently preferred embodiments of the invention for the purpose of illustration thereof, and not by way of limitation of the invention, and in which like characters refer to corresponding elements throughout the several views,  FIGS. 1 and 2  illustrate an I-shaped metal stud generally indicated by reference character  10  and including a neck  11  and flanges  12  to  15  outwardly depending from and normal to neck  11 . Neck  11  has a selected thickness indicated by arrows Z in  FIG. 1 . The thickness of flanges  14  and  15  is identical to the thickness of neck  11 . The thickness of flanges  12  and  13  is twice that of neck  11  because the metal is doubled back, or bent back, on itself to form flanges  12  and  13 . Doubling the thickness of flanges  12  and  13  is important because it makes the I-stud  10  significantly stronger and more resistant to forces which act normal to flanges  12 ,  13  in the direction of arrow  200  and which tend to cause stud  10  to bend, or flex. Neck  11  includes a flat front surface  201  and a flat back surface  202  parallel to and spaced apart from surface  201 . Neck  11  also includes a first elongate side  203  and a second elongate side  204  parallel to the first elongate side  203 . Side  203  generally extends the entire length of flanges  13  and  14  and of stud  10 . Flanges  13 ,  14  outwardly depend from side  203 . Side  204  generally extends the entire length of flanges  12  and  15  and of I-stud  10 . Flanges  12  and  15  outwardly depend from side  204 . 
     A plurality of generally rectangular openings  16  to  19 ,  20 ,  21  are formed through neck  11 . The shape and dimension of each of the openings can vary as desired. The area of each opening  16  to  19  is calculated by multiplying the length U times the width D. Each opening  16  to  19  has a shape and dimension equivalent to the other openings  16  to  19 . The area of each generally rectangular opening  20 ,  21  is also calculated by multiplying the length of the opening times the width of the opening. When the areas of each opening  16  to  21  are summed, a cumulative area of the openings is obtained. This cumulative area includes the area of openings  16  to  19 ,  20 ,  21  and of any other comparable openings in neck  11 . Circular openings like openings  25  and  26  are formed through neck  11  to facilitate threading electric wiring and other cables or lines through I-stud  10 . The circular area of these openings  25 ,  26  are included when calculating the cumulative area of the openings in neck  11 . Openings  16  to  19  also have a cumulative cross-sectional area. The cumulative cross-sectional area of openings  16  to  19 ,  20 ,  21  represents the area which is not available to heat for direct transmission from one elongate side  203  of neck  11  to the other elongate side  201  of neck  11 . The cross-sectional area of openings  17 ,  21 ,  16  is calculated by multiplying the width of neck  11 , indicated by arrows R in  FIG. 4 , times the height spanned by the openings, which height is indicated by arrow N in  FIG. 4 . The cross-sectional area of other openings  18 ,  20 ,  19  in neck  11  is similarly calculated. The cross-sectional area of all the openings in neck  11  is summed to obtain the cumulative cross-sectional area. The cross-sectional area of each circular opening  25 ,  26  is also included in the cumulative cross-sectional area because these openings also interfere with the transmission of heat from side  203  to  201 . Similarly, when the cumulative cross-section area of the openings  43 ,  44 ,  48  in stud  40  is calculated, the cross-sectional area of the openings  51 ,  52  provided for electrical, plumbing, and other lines is included. The cross-sectional area of a circular opening  25 ,  26  equals the diameter (or height) of the opening multiplied by the width R of neck  11 . 
     The surface area on the front of neck  11  equals the overall area of neck  11  minus the cumulative area of all the openings  16  to  21 ,  25 ,  26  formed through neck  11 . The overall area of neck  11  equals the width of neck  11 , indicated by arrows  230  in  FIG. 2 , multiplied by the height of neck  11 , indicated by the sum of the distances indicated by arrows A, B, C plus the remaining height of stud  10  (not shown). 
     The surface area of the back of neck  11  is equivalent to the surface area on the front of neck  11 . The surface area on the front of neck is generally equal to the surface area of side  201  plus the surface area of side  203  plus the surface area of the venturi bridges  22 ,  24 ,  23  in stud  10 . 
     Each venturi bridge  22  to  24  is adjacent at least one of openings  16  to  21 ,  25 ,  26  and has a surface area on the front of neck  11  and a surface area on the back of neck  11 . Each venturi bridge  22  to  24  extends between sides  201  and  203 . In  FIG. 2 , the surface areas of venturi bridges are flat, as are the surface areas of sides  201  and  203 . This need not be the case. The surface areas of bridges  22  to  24  and side  201  and  203  can be contoured. For example, in  FIG. 3A , ribs or raised areas  45  and  46  are formed on venturi bridges  50  and  50 A (but not on venturi bridges  49  and  49 A). Since each venturi bridge has a generally orthogonal shape, the surface area of each venturi bridge  22  to  24  on the front of neck  11  is calculated by multiplying the width of each bridge times the height of each bridge. The surface area of bridge  24  on the front of neck  11  is calculated by multiplying the width, indicated by arrows D times the height, indicated by arrows F. The surface area of venturi bridge  22  is calculated by multiplying the width, indicated by arrows D, times the height, indicated by arrows E. The surface area of venturi bridge  23  is calculated by multiplying the width, indicated by arrows D, times the height. The height of bridge  23  is the same as that of bridge  22 . The cumulative surface area of bridges  22  to  24  on the front of neck  11  (and any other venturi bridges in stud  10 ) is calculated by summing the surface area of each bridge  22  to  24  on the front of neck  11 . The surface area of each bridge  22  to  24  on the back of neck  11  is similarly calculated. In stud  10 , the surface area of bridges  22  to  24  on the back of neck II equals the surface area of bridges  22  to  24  on the front of neck  11 . 
     Bridges  22  to  24  also have a cumulative cross-sectional area. The cumulative cross-sectional area of bridges  22  to  24  represents the area which is available to heat for direct transmission from one elongate side  203  of neck  11  to the other elongate side  201  of neck  11 . The cross-sectional area of bridges  17 ,  21 ,  16  is calculated by multiplying the width of each bridge, indicated by arrows R in  FIG. 4 , times the height of the bridge. The cross-sectional area of all the venturi bridges in neck  11  is summed to obtain the cumulative cross-sectional area of the venturi bridges. The cross-sectional area of venturi bridge  24  equals the width, indicated by arrows R in  FIG. 4 , times the height, indicated by arrows P in  FIG. 4  (and arrows F in  FIG. 2 ). The cross-sectional area of venturi bridge  22  equals the width, indicated by arrows R in  FIG. 4 , time the height, indicated by arrows Q in  FIG. 4  (and arrows E in  FIG. 2 ). The cross-sectional area of bridge  23  equals the cross-sectional area of bridge  22 . 
     I-stud  30  illustrated in  FIG. 3  is constructed in accordance with an alternate embodiment of the invention. The stud  30  includes circular openings  38  extending through neck  30 A to facilitate the passage of electrical, plumbing, and other lines through neck  30 A. A plurality of openings  32 , 33 ,  36 ,  37  are formed through stud  30 , producing a plurality of venturi bridges  31 ,  35 ,  34 . Each venturi bridge is adjacent at least one opening. For example, venturi bridge  34  is adjacent opening  37  and opening  33 . Venturi bridge  31 A is adjacent opening  33 A. Venturi bridge  31 B is adjacent opening  32 A. Each venturi bridge  31 ,  31 A,  31 B,  35 ,  34  has a width equivalent to the width of the portion of the opening(s) to which it is adjacent. The portion of each opening  32 A,  33 A,  32 ,  33 ,  36 ,  37  adjacent a venturi bridge in  FIG. 3  has an equivalent width indicated by arrows  231 . If a venturi bridge  34  is intermediate and adjacent a portion of each of pair of openings  33  and  37 , and the portion of one opening adjacent the venturi bridge is wider than the portion of the other opening that is adjacent the venturi bridge, the length of the venturi bridge is equal to the width of the portion with the smaller dimension. When a venturi bridge  31 A is at the bottom  39  (or top) of a stud  30 , the length of the venturi bridge is equal to the width of the opening  33 A to which the bridge is adjacent, and is not equal to the width, indicated by arrows  232 , of the bottom of stud  30 . Neck  30 A includes sides  30 B and  30 C. 
     The cumulative area of all the openings formed in neck  30 A of stud  30  is determined by adding together the area of each opening in neck  30 A. The cumulative surface area on the front (or back) of neck  30 A for the venturi bridges in stud  30  is determined by adding together the surface area on the front (or back) of neck  30 A for each venturi bridge. On the other hand, the cross-sectional area of the openings formed through neck  30 A is determined by selecting the axis  233 ,  234  that passes through openings having the greatest cumulative cross-sectional area. Axes  233  and  234  are parallel to the elongate centerline of stud  30 . The elongate centerline is generally parallel to the flanges (for example, flanges  14  and  15  in  FIG. 1 ) extending along the sides of neck  30 A. If the openings through which axis  234  extends have a greater cumulative cross-sectional area than the openings through which axis  233  extends, the cumulative cross-sectional area of neck  30 A equals the cumulative cross-sectional area of the openings through which axis  234  extends. 
     In  FIGS. 2 and 4 , the length of an “opening-venturi bridge unit” is indicated by arrows B. The length of another “opening-venturi bridge unit” is indicated by arrows A in  FIG. 2  and is equivalent to the length indicated by arrows B. In  FIG. 4 , arrows N indicate the cumulative length of openings  16 ,  21 ,  17 . In  FIG. 3A , arrows M indicate the length of opening  44 . In  FIG. 4 , arrows O indicate the length of a portion of the openings  18 ,  20 ,  19  shown in  FIG. 4 . 
     I-stud  40  illustrated in  FIGS. 3A and 6  includes a neck  54  and flanges  41 ,  42 ,  56 ,  57 . The strength of flanges  41 ,  42 ,  56 ,  57  is significantly increased because the metal forming the flanges is doubled over on itself. Neck  54  includes front  54 A, back  54 B, a first elongate side  40 A extending the length of stud  40 , and a second elongate side  40 B extending the length of stud  40 . A plurality of openings  43 ,  44 ,  48  are formed through neck  54 . The area of each opening  43 , 44 ,  48  is calculated by first multiplying the width, indicated by arrows L, times the height indicated by arrows  240  to obtain a first value. Then, the width, indicated by arrows J, of the smaller tip of the opening is multiplied by the height, indicated by arrows K, of the small tip to obtain a second value. The first and second values are added to obtain the area of opening  44 . Openings  44 ,  43 , and  48  each are of equal shape and dimension, although this need not be the case. The area of the small opening at the bottom  53  of stud  40  is calculated by multiplying the height, indicated by arrows V, times the width, indicated by arrows L. Stud  40  includes venturi bridges  49 ,  50   49 A,  50 A. Each venturi bridge extends between sides  40 A and  40 B. The surface area of the venturi bridge  49  on the front  54 A of neck  54  is calculated by multiplying the height, indicated by arrows H, times the width, indicated by arrows J. The surface area of bridge  49 A on the front of neck  54  is equal to that of bridge  49 . The surface area of venturi bridge  50  on the front of neck  54  is calculated by multiplying the height, which is equal to the height H of bridge  49 , times the width, indicated by arrows L. The surface area of bridge  50 A on the front of neck  54  equals that of bridge  50 . The surface area of each bridge on the back  54 B of neck  54  is equal to the surface area of the bridge on the front of neck  54 , although that need not be the case. Ribs or detents  45 ,  46  do not significantly alter the surface area of bridges  45  and  46 . The cumulative surface area of the venturi bridges on the front of neck  54  is calculated by summing the surface area of each bridge. The cumulative area of openings  51 ,  52 ,  43 ,  44 , etc. is calculated by summing the area of each opening. The cumulative cross-sectional areas of the openings and venturi bridges is calculated in the manner earlier described for stud  10 . 
       FIGS. 5 ,  8  to  11  illustrate the components of a panel structure utilized to construct the roof of a building in accordance with the invention. The panel structure of  FIG. 5  can also, if desired, be utilized in constructing the wall of a building. The panel structure in  FIG. 5  includes a foam panel or board  66  shown in ghost outline. Panel  66  includes a bottom  62 , a top (not shown) parallel to bottom  62 , an outside face (i.e., the top of the roof  60 , an inside face  61  (i.e., the ceiling inside a building structure), a first side  63 , and a second side (not shown) parallel to first side  63 . Side  63  includes spaced apart peripheral edges  64  and  65 . An elongate groove  111  having a U-shaped cross-section is formed in side  63 . A groove similar to groove  111  is also formed in the second side of panel  66 . 
     Foam panel  110  is also indicated in ghost outline and is identical in shape and dimension to panel  66 . An elongate groove  112  is formed in the second side of panel  110 . Groove  112  is identical to the groove formed in the second side (not visible) of panel  60 . The shape and dimension of groove  112  is identical to that of groove  111 , although groove  112  opens in a direction opposite that of groove  111 . 
     H-shaped metal stud  70  is similar to metal studs  10 ,  30 , and  40 , except that stud  70  does not include openings formed through the neck  75  of stud  70 . In addition, neck  75  is not flat like necks  11 ,  30 A,  54 . Instead, neck  75  has sections or ribs  80 ,  76 ,  77 , etc. that are offset from one another. 
     One principle function of the openings and venturi bridges formed in the necks of studs  10 ,  30 , and  40  is to reduce the conduction of heat into the necks of the studs. This is important in the combination of the invention because C-shaped or I-shaped metals studs are used to interconnect and secure foam panels. Foam panels provide efficient thermal insulation. This thermal insulation can be breached and bypassed if heat is readily transmitted from the neck of the metal studs to foam panels and from foam panels into the interior space in a building. The structure of studs  10 ,  30 ,  40  minimizes the transfer of heat at the neck-foam panel interface. In contrast, the panel structure of  FIG. 5  does not require that the conduction of heat in the neck  75  of metal stud  70  be minimized, although the offset ribs  80 ,  76 ,  66 , etc. do function to limit the transfer of heat from neck  75  to the side  63  of a panel  66 . The panel structure of  FIG. 5  prevents the transmission of heat from the outside face  60  to the inside face  61  by using foam panels  60 ,  110  in which the inside face  61  is spaced apart from the bottom flanges  73  and  74 . In addition, edge  65  of side  63  is supported by an elongate L-shaped structural member  86 . Member  86  is connected to stud  70  by a plurality of spaced apart elongate structural arms or members  81 . Since the cumulative width of spaced apart arms  81  is much less than the total length of a stud  70 , the heat transmitted from flange  70  and through arms  81  to member  86  is greatly minimized. The maximum width  81 W of an arm  81  is typically only 0.1″ to 2″ per foot of stud length. In other words, the total cumulative width of the arms  81  used along the length of a stud is about 0.8% to 25% of the length of the stud, preferably 4% to 10%. If desired, openings  89  can be formed through arms  81  to further minimize the transmission of heat from flange  70  through arms  81  to member  86 . Any desired means can be utilized to secure and arm  81  to flange  70  and member  86 . It is presently preferred to rivet upper end  82  through aperture  84  to rib  77  of flange  70 , and, to rivet lower end  83  through aperture  85  to leg  87  of member  86 . Leg  87  depends from leg  88  of member  86 . A plurality of spaced apart apertures  123  are formed through flange  74  to permit an arm  81  to slide therethrough in the manner illustrated in  FIG. 5 . 
       FIG. 11  illustrates an arm  81 A which can be utilized in place of arm  81 . Arm  81 A includes upper end  135  with aperture  137  formed therethrough, and includes lower end  136  with aperture  138  formed therethrough. Detents  81 B,  81 C strengthen arm  81 A. 
     Stud  70  includes flanges  71  and  72  along one side and includes flanges  73  and  74  along the other side. Neck  75  extends between flange pair  71 - 72  and flange pair  73 - 74 . Neck  75  includes parallel, interconnected, offset panels or ribs  80 ,  76 ,  77 ,  78 ,  79 . As noted, the offset design of ribs  76 - 80  functions to split between panels  66  and  110  the quantity of heat that is transmitted from neck  75  to the sides of panels  66  and  110 . If desired, however, a neck  75 A which is essentially flat and lies in one plane in the manner of necks  54 ,  30 A and  11  can be utilized in place of the neck  75  illustrated in  FIG. 5 . In  FIGS. 8 and 10  the offset ribs  76 - 80  of neck  75  are not, for the sake of clarity, depicted. Nor are the offset ribs of arm  81  depicted in  FIG. 8 . In  FIG. 10 , arms  81 A are shown being used in place of arms  81 . 
     In  FIG. 8 , foam panel  110  is omitted for purposes of clarity. Foam panel  66  is in part obscured behind sloped stud  70  and is in part visible because it extends down past flange  74 . When foam panel  110  is put in place, the second side is placed against stud  70  intermediate flanges  71  and  74  in the manner illustrated in  FIG. 5 , and, another stud is placed along the first side of panel  110  in the same manner that stud  70  extends along the first side of panel  66  in  FIG. 5 . The stud placed along the first side of panel  110  has a C-shape if another foam panel will not be placed adjacent the first side of panel  110 . If an additional foam panel will be placed adjacent the first side of panel  110  in the same manner that panel  110  is placed against the first side of panel  66  in  FIG. 5 , then, as would be appreciated by those of skill in the art, the stud placed along the first side of panel  110  is I-shaped so that the stud has flanges which will support both panel  110  and the additional foam panel. 
     In  FIG. 8 , foam panel  66  and foam panels adjacent panel  66  are notched to form a V-shaped notch including planar flat rectangular surface  201  and the bottom of flange  74 . This notch permits panel  66  and flange  70  to be displaced downwardly in the direction of arrows  235  and  236  to engage and conform to the top of the wall  300 . Surface  201  slides along the outside of foam panel  90  and flange  42 . The bottom of flange  74  rests on sloped top surface  202  of vertically oriented wall  300 . V-shaped bracket  100  is riveted to stud  40 A and to member  86 . Stud  40 A is equivalent in shape and dimension to stud  40 , except that the top of stud  40 A and of panel  90  are cut to form sloped surface  202  so that when foam panel  90  is installed in the manner shown in  FIG. 8 , the top of panel  90  and top of stud  40 A cooperatively form sloped surface  202 . 
     In roof  301 , panel  66 , along with other panels coplanar with panel  66 , extends at least to dashed line  237 . See  FIG. 16 . In other words, panel  66  extends from dashed line  237  in the direction of arrow X, but does not extend from dashed line  237  in the direction of arrow Y. Although not necessary, it is preferred that panel  66  completely cover the portion of the sloped surface  202  over which panel  66  extends. This is important in forming an efficient thermal seal between roof  301  and wall  300 . If panel  66  extends only partially across surface  202 , this in effect reduces the R value (i.e., reduces the ability to prevent the transmission of heat) of the roof—wall joint or interface. The ability to form a well sealed thermal envelope at the roof—wall interface is an important advantage of the invention. 
       FIG. 9  further illustrates the roof construction of  FIG. 8  including foam panels  66  and  110 , flanges  70  and arms  81 . The shape and dimension of each orthogonal panel  66 ,  110 , and  110 A is identical, although this need not be the case. The shape and dimension of the roof panels can vary as desired. The width  238  of a foam roof panel is presently two feet. The thickness  239  of a foam roof panel is presently twelve inches. The thickness, width, and length of a foam roof panel can vary as desired. Since the width  238  of a foam roof panel  66  is two feet, each parallel pair of metal studs  70  supporting a panel  66  is about two feet apart. Since the thickness of a roof panel is twelve inches, the outside face  60  is twelve inches from the inside face  61 . 
       FIG. 10  illustrates one possible construction of the crown of a roof in the practice of the invention. In  FIG. 10 , stud  70  and foam panel  66  on one side of the roof abut against a comparable stud  130 —foam panel  66 A structure on the other side of the roof. Metal panel  120  is riveted or otherwise secured to studs  70  and  130 . The upper most ends of studs  70  and  130  rest, along with foam panels  66  and  66 A, on vertically oriented cross beam or support beam  132 . In  FIG. 10 , beam  132  is normal to the sheet of paper on which the drawing is inscribed. Bracket  121  is riveted to flanges on studs  70  and  130 . V-shaped bracket  121 A is riveted to beam  132  and member  86 . V-shaped bracket  121 B is riveted to beam  132  and member  131 . 
       FIG. 6  illustrates a structural panel used in the construction of a wall in a building. The structural panel illustrated in  FIG. 6  can also be utilized to construct the roof of a building. 
     In  FIG. 6 , the interface between stud  40  and a pair of foam panels  90  and  100  is illustrated. I-stud  40  is illustrated in  FIG. 3A . As earlier noted, the strength of stud  40  is significantly improved because each flange  41 ,  42 ,  56 ,  57  consists of metal which is doubled over on itself and which is therefore thicker than the metal comprising neck  54 . Typically each flange  41 ,  42 ,  56 ,  57  is twice as thick as the neck  54 . This result can, of course, be varied depending on the thickness and configuration of the metal plate(s) used to form a stud  40 . Each flange might only be 1.5 times as thick as neck  54 , or, might be three times as thick as neck  54  if the portion of the metal plate used to form the flanges had a different thickness than the portion of the metal plate used to form neck  54 . The thickness of a flange can be increased by attaching another piece of material to the flange. 
     Orthogonal foam panel  90  includes outside face  91  (i.e., the face exposed to the outdoors), inside face  92  (i.e., the face exposed to the interior of a building) parallel to face  91 , top  93 , a bottom (not visible) parallel to top  93 , a first rectangular edge  94  extending between the inside face  92  and the outside face  91 , and a second rectangular edge (not shown) parallel to edge  94  and extending between inside face  92  and outside face  91 . Edge  94  is adjacent and contacting the back  54 B of neck  54 . Edge  94  preferably fits snugly between flanges  56  and  57  such that flange  57  contacts inside surface  92  and flange  56  contacts outside surface  91 . 
     Foam panel  100  includes outside face  101  (i.e., the face exposed to the outdoors), inside face  102  (i.e., the face exposed to the interior of a building) parallel to face  101 , top  103 , bottom  105  parallel to top  103 , a first rectangular edge (not visible) extending between the inside face  102  and the outside face  101 , and a second rectangular edge  104  parallel to the first rectangular edge and extending between inside face  92  and outside face  91 . Edge  104  is adjacent and contacting the front  54 A of neck  54 . 
     Edge  104  preferably fits snugly between flanges  41  and  42  such that flange  41  contacts inside face  102  and flange  42  contacts outside face  101 . This configuration of the structural combination of stud  40  and of panel  100  (or  90 ) strengthens stud  54  because panels  90  and  100  resist compression and therefore help prevent stud  54  from bending when a shear force is applied to stud  54  in the direction of arrow  242 . Similarly, flanges  41  and  42  function to hold the edge  104  in a fixed position, which increases the ability of edge  104  and panel  100  to resist a force acting on panel  100  in the direction indicated by arrow  242 . In the roof panel construction illustrated in  FIG. 5 , the portion of each side  63  of a foam panel extending between a pair of flanges  72  and  73  also preferably also fits snugly between such flanges  72 ,  73 . 
     By way of example, and not limitation, during construction of a wall, a series of vertically oriented studs  40  is placed on eighteen inch centers. A foam panel  90 ,  100  about eighteen inches wide is placed between each adjacent pair of spaced apart flanges such that the first edge (for example, edge  94 ), i.e., the right hand edge, of a vertically oriented panel contacts the back  54 B of the neck of one stud and the second edge (for example, edge  104 ), i.e., the left hand edge of a vertically oriented panel contacts the front of the neck of another stud. Consequently, as shown in  FIG. 17 , each foam panel is sandwiched between a pair of vertically oriented metal studs  40 ,  40 D,  40 E. Each stud  40 ,  40 D,  40 E runs along a vertically oriented edge  94 ,  104  of a foam panel. L-shaped support members  105 A and  108  run along the bottom  105  of the foam panels and of the studs  40 ,  40 D,  40 E. Members  105 A and  108  are riveted or otherwise fastened to each stud  40 ,  40 D,  40 E. Metal members  105 A and  108  preferably do not contact each other. This prevents heat in the ambient air from being transmitted from member  108  to member  105 A. A single U-shaped member can be utilized in place of members  105 A and  108 . Such a U-shaped member would span across the bottom  105  of each panel from the inside face  102  to the outside face  101  of the panel. The use of such a U-shaped member is discouraged, but not prohibited, because it facilitates the transmission of heat from the outside of the panel to the inside of the panel via the metal U-shaped member. Studs  40 D,  40 E are identical to stud  40  except that studs  40 D,  40 E each only have one pair  56 - 57  or  41 - 42  of flanges. In  FIG. 17 , the openings  43 ,  44 ,  48 , etc formed through the neck of stud  40 D are omitted for the sake of clarity. 
     A pair of U-shaped members  111 ,  111 A ( FIG. 17 ) also run along the top  103 ,  93  of the panels in the same manner that members  105 A and  108  run along the bottom  105  of the panels. In the event that the top of a structural wall panel is sloped in the manner evidenced by surface  202  in  FIG. 8 , then members  111  and  111 A take on a V-shape so they can conform to the top of the wall panel. The U-shaped (or V-shaped) members extending along the top of a wall panel are riveted or otherwise attached to each stud  40 . At the end of each vertically oriented wall panel, the vertical edge of a foam panel is supported by a stud  40 D,  40 E that is C-shaped, i.e., that only includes one set of flanges  56 ,  57  and does not include the second set of flanges  41 ,  42 . The second set of flanges is not necessary because the stud is at the end of the wall panel. 
     As can be seen, each wall panel of the type illustrated in  FIGS. 6 ,  17  consists of foam panels supported by an interconnected metal frame work consisting of spaced apart, parallel, vertically oriented studs  40 ,  40 D,  40 E and horizontally oriented structural support members  105 A,  108 ,  111 ,  111 A extending along the top and bottom of the foam panels. This structure is unusually strong, particularly when the flanges of a stud are thicker than the neck of a stud and/or when the flanges are reinforced by bending metal over on itself, by forming strengthening ribs or detents in the flanges, by attaching a strip of metal to the flanges, or by otherwise strengthening the flanges. 
     Limiting the transfer of heat from the neck  54  of a metal stud  40  to the edge  104  of a foam panel  100  at the neck  54 —edge  104  interface between neck  54  and edge  104  is critical in the practice of the invention. Heat transferred from the face  54 A of neck  54  to edge  104  can travel through the inside portion of panel  100  indicated by arrows S in  FIGS. 6 and 7  and can be transmitted at least in part into the inside of a residence or other building structure. As the cumulative area of openings formed in the neck  54  of a stud  40  increases, the ability of the neck  54  of stud  40  to transmit heat to edge  104  decreases. Openings formed in the neck  54  of a stud  40  are shown in dashed outline  48 B,  48 A,  43 A,  44 A in  FIG. 7 . The circular openings in neck  54  are omitted in  FIG. 7  for the sake of clarity. The cumulative area of openings  48 B,  48 A,  43 A,  44 A (and any other openings formed through neck  54 ) is calculated in the manner earlier described. The rectangular surface area of edge  104  is calculated by multiplying the height of edge  104  by the width of edge  104 . In order to limit the transmission of heat from neck  54  to edge  104 , the ratio of the surface area of edge  104  to the cumulative area of openings  48 B,  48 A,  43 A,  44 A should be in the range of 10:1 to 1.33:1, preferably 5:1 to 1.33:1. 
     Similarly, as the surface area of venturi bridges on the front (or back) of the neck  54  decreases, the ability of neck  54  to transmit heat to edge  104  decreases. The cumulative surface area of venturi bridges on the front  54 A of neck  54  can be calculated in the manner earlier described. The ratio of the surface area of edge  104  to the cumulative surface area of the venturi bridges in neck  54  should be in the range of 25:1 to 4:1, preferably 25:1 to 10:1, to limit the transmission of heat from neck  54  to edge  104 . In  FIG. 7 , the height of each venturi bridge is indicated by arrows H 1 , H 2 , H 3 , H 4 , H 5 , respectively. Each distance H 1 , H 2 , H 3 , H 4 , H 5  is equal to the others. 
       FIGS. 12 to 15  illustrate a bracket  140  utilized to secure a wall panel to a concrete foundation  203 , wood frame foundation, or other foundation. Bracket  140  includes a foot  141  with oblong aperture  143  formed therethrough. Bracket  140  also includes a rectangular body  142  normal to and depending from foot  141 . During installation of a wall panel a plurality of brackets is attached to foundation  203  at desired intervals. These intervals preferably correspond to the intervals between the studs  40 A in a wall panel. The brackets  140  are attached to foundation  203  by driving bolts through openings  143  into the foundation. Or, screws or other fasteners can be inserted through openings  143 A. After the brackets  140  are attached to foundation  203 , a wall panel is positioned on the brackets  140  in the manner illustrated in  FIG. 15  and the brackets  140  are riveted or otherwise secured to member  105 A and/or studs  40 A. 
       FIG. 16  illustrates a roof panel constructed utilizing metal studs and panels of the type shown in  FIG. 5 . The panel in  FIG. 16  includes I-studs  70  and C-studs  70 A. Foam panels  60 ,  60 A,  60 B, and  110  are supported intermediate the studs. L-shaped member  86 A (identical to member  86 ) is secured to stud  70 A by members  81 . Each member  81  is riveted or otherwise attached at one end to member  86 A and at the other end to stud  70 A. The flange  70 F of stud  70 A has spaced apart openings cut therethrough comparable to opening  123  ( FIG. 5 ) such that a member  81  can slidably extend through the opening in flange  70 F in the same manner that member  81  extends through opening  123  in  FIG. 5 . Elongate metal support members  261  can be riveted or otherwise connected to studs  70 ,  70 A to hold the studs together in spaced apart relationship. 
     The studs  10 ,  30 ,  40 ,  40 A,  70  utilized in the practice of the invention are preferably fabricated from metal, but can be fabricated from any desired material. When metal is utilized it has a thermal conductivity greater than 0.030 g-cal/(sec.)(sq. cm.)(degree C./cm.) at eighteen degrees Centigrade. The preferred metal is steel. The construction of the invention, including flanges  71 ,  72 ,  73 ,  74  that are each formed by folding the edge of a panel over on itself, enables lightweight  20  gauge steel panels to be utilized to roll and form studs  10 ,  20 ,  40 ,  40 A,  70  from a flat panel of steel. The ability to use such a thin gauge of metal reduces the cost of constructing the panels of the invention. 
       FIG. 17  illustrates a wall panel constructed utilizing metal studs and panels of the type shown in  FIG. 6 . The panel in  FIG. 17  includes I-studs  40  (i.e., with a cross-sectional area in the shape of an I) and C-studs  40 D (i.e., with a cross-sectional area in the shape of a C). Foam panels  100 ,  90 ,  90 A are supported intermediate the studs. L-shaped support members  111 A and  111  extend along the top of the foam panels and are riveted or otherwise connected to the tops of the metal studs. L-shaped support members  105 A and  108  extend along the bottom of the foam panels and are riveted or otherwise connected to the bottoms of the metal studs. Openings for window or doors can be formed in wall panels. Channels can be cut in the wall panels for electrical wiring, plumbing, etc. 
     In use, wall panels of the type illustrated in  FIGS. 6 and 17  (or of the type illustrated in  FIG. 5 ) are constructed. Roof panels of the type illustrated in  FIGS. 5 and 16  (or of the type illustrated in  FIG. 6 ) are constructed. The roof and wall panels are transported to a construction site. Brackets  140  are mounted on the foundation  203  around the periphery of the foundation at spaced apart intervals in the manner illustrated in  FIG. 15 . The wall panels are then positioned along the periphery of the foundation. Bottom portions of each panel are secured to body  142  of each bracket  140  in the manner illustrated in  FIG. 15 . A cross-beam  132  or other support is positioned with supports that extend to the walls or to the foundation. Roof panels are mounted on the top of the wall panels and of the cross-beam  132  in the general manner illustrated in  FIGS. 8 and 10  to insure a thermal seal is formed between the roof panels and top of the wall panels. 
     If desired, once a wall panel of the type shown in  FIG. 17  is constructed, sheet rock or plywood or other material can be attached to the flanges of the metal studs before the wall panel is transported to a construction site to erect a residence or other building structure. Such paneling or other material can also be attached to the metal studs in the wall panel after the panel is transported to a construction site at which a building structure is erected. Similarly, plywood or other material can be attached to roof panels of the type shown in  FIG. 16  before or after the panels are transported to a construction site to assemble a building structure. When sheet rock or other finishing materials are mounted on a wall or roof panel before the panels are transported to a construction site, the erection at the site of outer walls and roof of a one story or multi-story building structure can be accomplished in a day or less. 
     The foam used in panel  60 ,  90 ,  100 , etc. can vary as desired, but expanded polystyrene foam panels are presently preferred, in part because they are lightweight and do not exude harmful chemicals. 
     Panels constructed in accordance with the invention can be utilized to construct flat or sloped roofs. Sloped roofs usually have a slope of at least 2/12.