Thermal stud or plate for building wall

Abstract

A metal thermal stud / plate has a center web with geometrically-shaped apertures spaced longitudinally along its centerline. The apertures define alternatingly-positioned narrow necks of material therebetween near ends of the center web. The narrow necks minimize thermal conductivity between the spaced flanges, but adjacent ones of the narrow necks are longitudinally misaligned due to their alternating positions to thus prevent forming a weak longitudinally-extending fold line in the stud / plate, thus maintaining its strength. In one form, the narrow necks are at most about 0.100 inches wide without substantially degrading the strength of the studs / plates, or can be a ratio of neck width to center web of as low as 0.09:4 down to 0.03:4. A building wall frame includes a plurality of the metal studs / plates and foam insulated panels with edges engaging the center webs of adjacent studs / plates to thus stabilize the metal studs / plates.

Description

BACKGROUND[0001]The present invention relates to structural beams, such as metal studs or plates, configured for strength and thermal non-conductivity and suitable for use in building walls. The invention further relates to a method and apparatus for assembling a thermally insulated building structure.[0002]Residential and other building structures are often constructed by erecting a frame consisting of wooden two by fours and other wood lumber. Insulation, sheet rock, and siding are attached to the frame. However, wood has disadvantages, such as being susceptible to termite and insect damage, and warping after it is installed. Also, wood shortages are increasing the expense of wood-frame buildings, and installation is labor intensive.[0003]Another construction technique utilizes metal studs to construct walls. However when metal studs are used in a building wall (especially an exterior wall) or floor, thermal loss through the stud can be significant. Prior art thermal studs are kno...

AI Technical Summary

Benefits of technology

[0006]In another aspect of the present invention, a thermal structural component for buildings includes a metal structural component, such as a stud or plate component, having a center web and spaced flanges forming one of an I-beam shape, channel shape, or a C-beam shape. The center web includes apertures spaced along the center web that define therebetween a series of narrow necks of material located in an outer 25% of the center web. The series of narrow necks are located at alternating ends of the center web and minimize thermal conductivity between the spaced flanges, but the narrow necks are longitudinally misaligned and located near the spaced flanges to prevent forming a weak longitudinally-extending fold line in the structural component. By this arrangement, a strength of the structural component is substantially maintained.

[0007]In another aspect of the present invention, a thermal structural component for buildings includes a metal structural component, such as a stud or plate component, having a center web and spaced flanges forming one of an I-beam shape, channel shape, or a C-beam shape. The center web includes apertures along the center web that define therebetween repeating narrow necks of material located in the center web, the narrow necks being at most about 0.100 inches wide and substantially minimizing thermal conductivity between the spaced flanges, but the narrow necks being longitudinally misaligned to prevent forming a weak longitudinally-extending fold line in the structural component and to thus substantially maintain a strength of the structural component.

[0008]In another aspect of the present invention, a thermal structural component for buildings includes a metal structural beam component having a center web and spaced flanges forming one of an I-beam shape, channel shape, or a C-beam shape; the center web including apertures spaced longitudinally along the center web that define therebetween a series of narrow necks of material, adjacent ones of the narrow necks defining a fold line that is at least 45 degrees angled to a length of the stud, the apertures with narrow necks substantially minimizing thermal conductivity between the spaced flanges, but the narrow necks being longitudinally misaligned to prevent forming a weak longitudinally-extending fold line that extends parallel the length of the beam component, such that the arrangement substantially maintains the strength of the beam component.

[0013]In one aspect of the present invention, a building wall frame includes a plurality of thermal structural components as defined in any of the above concepts, the components being spaced apart but arranged to define a wall; and a plurality of structural insulated panels with edges engaging the center webs of adjacent components and including front and rear faces engaging an inside of the flanges of the components in a manner stabilizing the components in the assembly.

Problems solved by technology

However, wood has disadvantages, such as being susceptible to termite and insect damage, and warping after it is installed.

Also, wood shortages are increasing the expense of wood-frame buildings, and installation is labor intensive.

However when metal studs are used in a building wall (especially an exterior wall) or floor, thermal loss through the stud can be significant.

However, in known studs, the narrow points which minimize thermal transfer are aligned and thus weaken the stud by creating a “fold line” weakness in its center web that extends longitudinally in the stud.

Further, the “fold line” weakness reduces the stud's strength and / or limits a narrowness of the narrow points, which in turn limits the ability to minimize thermal conductivity through the studs.

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