Thermal stud foamed panel for buildings

Abstract

A completely insulated building, wall, roof and floor panels each with inner and outer surfaces that have no thermal bridging between the inner and outer surfaces of the panels. Construction of the panels are undertaken in a factory and shipped to the building site where the panels are assembled and secured together into building structures. The panels each include a wall, roof or floor wood or metal frame with top, bottom and side plates. The frame is spaced from an outer layer of sheathing that is dimensioned to match the length and width dimensions of the sheathing creating a void therebetween. Curable liquid foam is introduced partially around and internally of the frame and continuously into the void between the equally dimensioned frame and sheathing without any thermal breaks between the frame and the sheathing. Once the foam has cured, the foam adhesively secures and bonds the frame and sheathing together. A water resistive barrier is adhesively secured to the sheathing, top, bottom and side plates of the panel.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority to U.S. Provisional App. No. 63 / 762,234, filed on Feb. 24, 2025, and titled THERMAL STUD FOAMED PANEL FOR BUILDINGS.SUMMARY OF THE INVENTION

[0002] The present invention relates to thoroughly insulated building, wall, roof and floor panels and more particularly to construction panels made in a factory and shipped to the building site where the panels are assembled into building structures. The panels include a wood or metal frame that is suspended over and above exterior sheathing in a foaming table with an open top and enclosing side walls and a floor. Liquid foam is introduced partially around the frame and completely below the frame. After the foam is cured, the panel is removed from the foaming table with the sheathing adhesively secured to the foam and the frame. Then a water resistive barrier is adhesively secured to the sheathing, top, bottom and side plates of the panel.

[0003] The present inventor has invented at least six inventions for wall, ceiling and floor building constructions incorporated here for construction referencing. They are:

[0004] a) Composite Reinforced Studs 10 commonly referred to as Bare Naked Tstuds with reinforcing dowels 12 between at least two lumber pieces 14, 16 protected by at least one of the following US design patents D936,242; D942,049; D941,946; D941,498; D938,618 and D1,033,679 and US utility U.S. Pat. No. 11,255,084 as shown in prior art FIGS. 1A and 1B.

[0005] b) Composite Foamed Reinforced Studs 20 commonly referred to as R19 Studs with reinforcing dowels 22 between at least two lumber pieces 24, 26 that are covered with foam 28 around dowels protected by at least one of the following U.S. Pat. Nos. 11,255,084; 10,731,332; 9,783,985; 9,677,264 and D938,618 as shown in prior art FIGS. 2A and 2B.

[0006] c) Outboard Foamed Studs 30 commonly referred to as Warm Studs with lumber 32 having its outer edge covered with foam 34 protected by at least one of the following US patent application and design patents Ser. No. 18 / 503,587; D938,618 and D1,024,362 as shown in prior art FIGS. 3A and 3B.

[0007] d) Double S-Shaped Foamed Metal Studs 40 with foam 42 therearound commonly referred to as Rhino Studs protected by the following US design patent application Ser. No. 29 / 920,444 as shown in prior art FIGS. 4A and 4B.

[0008] e) Offset Joined Twin Studs 50,52,54 as shown in prior art FIGS. 5A, 5B and 5C.

[0009] f) Drain Strips 60 with open honeycombed core 62 and bug / pest screen 64 to be horizontally or vertically mounted on exterior sheathing protected by the following US utility patent application U.S. Ser. No. 18 / 185,984 as shown in prior art FIGS. 5A, 5B and 5C.

[0010] Foaming spray machines (such as Model No. PMC-PH2) are available from Polyurethane Machine Corporation, at One Komo Drive, Lakewood, New Jersey 08701. Polyurethane foams 82 (such as NCFI 11-037 InsulBloc SmartSPF and the like) are available from Barnhardt Manufacturing Company, at PO Box 1528, Mount Airy, North Carolina 27030.

[0011] Foam nonstick poly barriers or lumber wrap are typically made from woven polyethylene (PE), polypropylene (PP), or fabric with a UV-resistant coating. These materials provide durability, moisture resistance, and protection against sun exposure during transportation and storage. These barriers are resistant to spray foam permanently sticking to the barriers.

[0012] Samples of typical known wood products that work well with the present panel invention include spruce, pine and fir (SPF). SPF is a classification of softwood lumber made from a mix of spruce, pine, and fir species. Common uses of SPF are for framing, trusses, studs, joists, and general construction. Southern yellow pine (SYP) is a dense, strong softwood species primarily found in the southeastern U.S., Common uses of SYP are for structural framing, decking, pressure-treated lumber, and flooring. SYP is a high strength-to-weight ratio, excellent nail and screw holding capacity, and commonly used for pressure-treated wood due to its ability to absorb preservatives. LSL. Laminated veneer lumber (LVL) is a engineered wood product made by bonding thin layers of wood veneers together with adhesives. LVL is commonly used for beams, headers, rim boards, and truss components. LVL is a higher strength and consistency than solid lumber, less prone to warping or shrinking. Parallel strand lumber (PSL) is a high-strength engineered wood product made from long, thin wood strands for bonded together in parallel with adhesives. Common uses are for beams, columns, headers, and structural supports. PSL is stronger than LVL and LSL and is capable of carrying heavy loads, commonly used in commercial and high-load applications.

[0013] Floor trusses are prefabricated, engineered wood structures designed to span long distances in flooring systems. Floor trusses are commonly used in supporting floors in residential and commercial buildings. Floor trusses allow for large spans with minimal deflection and provide open webbing for easy mechanical, plumbing, and electrical installation.

[0014] Roof trusses are prefabricated triangular-shaped wooden frameworks that support roofs and are commonly used for residential and commercial roofing structures.

[0015] Roof trusses provide structural integrity while reducing the need for interior load-bearing walls, allowing for open-concept designs.

[0016] I-Joists are engineered wood joists consisting of a top and bottom flange (typically LVL or solid wood) and a plywood or OSB web in between, forming an “I” shape. I joists are commonly used for floors and roof framing. I joists are lighter, stronger, and more dimensionally stable than traditional lumber joists, allowing for longer spans with less material.

[0017] Preexisting structural insulated panels (SIPS) are high-performance building systems made of an insulating foam core sandwiched between two structural facings, usually oriented strand board (OSB). Key features of SIPS include that they provides structural support, insulation, and sheathing in one panel. SIPS typically consists of expanded polystyrene (EPS), extruded polystyrene (XPS), or polyurethane foam cores. SIPS are commonly used for walls, roofs, and floors in residential and commercial construction. SIPS are known for energy efficiency, strength, and fast installation compared to traditional framing. SIPS panels are commonly used in energy-efficient and green building designs due to their airtight construction and reduced thermal bridging. However, SIPS can delaminate over time, thermal bridging can occur at seams and connections, are susceptible to moisture damage, mold, and OSB degradation over time and are susceptible to moisture damage, mold, and OSB degradation and are moderately strong but not always hurricane-resistant.

[0018] There is a need for a Thermal Studs Ultimate Panel System (TSUPS) that is prefabricated at a manufacturing facility and delivered to building sites for simple panel connections to construct a building. The panel should have no thermal conductivity or thermal bridges between the inner and outer surfaces creating higher R values than traditionally labor built walls, and increased vertical and horizontal strengths that heretofore have yet to be realized.SUMMARY OF THE INVENTION

[0019] A completely insulated building, wall, roof and floor panels each with inner and outer surfaces having no thermal bridging between the inner and outer surfaces of the panels. Construction of the panels are undertaken in a factory and shipped to the building site where the panels are assembled and secured together into building structures. The panels each include a wall, roof or floor wood or metal frame with top, bottom and side plates. The frame is spaced from an outer layer of sheathing that is dimensioned to match the length and width dimensions of the sheathing. Curable liquid foam is introduced partially around and internally of the frame and continuously between the equally dimensioned frame and sheathing without any thermal breaks between the frame and the sheathing. Once the foam has cured, the foam adhesively secures and bonds the frame and sheathing together. A water resistive barrier is adhesively secured to the sheathing, top, bottom and side plates of the panel.

[0020] A principal object and advantage of the present invention is that the panels have no thermal bridging between the inner and outer surfaces. Using closed-cell spray or pour foam applied directly to lower portions of the studs and spaced sheathing, create a continuous thermal break while maintaining structural separation. Foam fills the void between the frame and sheathing and further partially fills the cavity around the studs, yet allowing for additional insulation options achieving higher R-values per inch and superior energy performance.

[0021] Another principal object and advantage of the present invention is that it offers customizable R-values by adjusting the foam thickness and type and accommodating additional insulation in the cavity.

[0022] Another principal object and advantage of the present invention is that it may be used any type of structural wood or metal stud, truss joist product, and any type of sheathing or cladding for superior wind load resistance (up to 1,000 pounds per linear foot) and racking strength, far exceeding SIP performance.

[0023] Another principal object and advantage of the present invention is that it is compatible with any sheathing material (e.g., OSB, plywood, SIP System) and framing member (e.g., RhinoStud™, Tstud™ and WarmStud™) all of which can be made from SPF, SYP, LVL, LSL, PSL, floor trusses, roof trusses, or I-joists, providing unmatched adaptability.

[0024] Another principal object and advantage of the present invention is that it can be manufactured by small, medium, or large facilities with minimal equipment investment, providing scalable solutions for manufacturers.

[0025] Another principal object and advantage of the present invention is that it simplifies production by applying foam directly onto sheathing and studs, reducing manufacturing steps.

[0026] Another principal object and advantage of the present invention is that it can be pre-drilled for wiring and plumbing, and can be easily adjusted on-site without sacrificing performance.

[0027] Another principal object and advantage of the present invention is that it is a lighter, modular panel that can be installed with minimal equipment, reducing labor costs and construction timelines.

[0028] Another principal object and advantage of the present invention is that it is compatible with any cladding material, including fire-rated options, and can adapt to project-specific needs.

[0029] Another principal object and advantage of the present invention is that it uses HFO-blown closed-cell foam with low GWP (~4) and produces minimal waste during manufacturing and installation.

[0030] Another principal object and advantage of the present invention is that it is a non-commodity product with distinct monetary advantages for licensees, requiring low-cost equipment investment and offering flexible licensing models.

[0031] Another principal object and advantage of the present invention is that it produces minimal waste due to its adaptable process and on-site modifiability. The panels can also incorporate recycled foam waste thereby further improving sustainability.

[0032] Another principal object and advantage of the present invention is that it is pre-engineered to meet stringent building codes, including hurricane resistance (Miami-Dade County) and seismic compliance (Los Angeles County).

[0033] Another principal object and advantage of the present invention is that it supports fire-rated claddings that can be applied as needed, enhancing fire safety for applications in wildfire-prone areas.

[0034] Another principal object and advantage of the present invention is that it stands out for its adaptability, structural integrity, superior thermal performance, and ease of manufacturing; addresses many of the limitations of SIPs; thereby making it a more flexible and cost-effective solution for modern construction. By providing manufacturers, builders, and developers with an adaptable, sustainable, and high-performance panel, the invention redefines the possibilities in panelized construction.

[0035] Another principal object and advantage of the present invention is that is a high-performance, fully integrated construction panel designed for floors, roofs, and walls. Each panel is manufactured by combining precision-aligned framing members with structural sheathing and a continuous layer of closed-cell spray foam insulation. The panel is highly adaptable and can be made from any wood product, including 2 by dimensional lumber (such as SPF, SYP LVL, LSL or PSL) treated or untreated lumber, floor trusses, roof trusses, or even I-joists, ensuring compatibility with diverse structural applications.

[0036] Another principal object and advantage of the present invention is that it is a panel that is thermally efficient, structurally robust, and ready for rapid on-site assembly. For walls, the system provides superior thermal breaks and wind resistance, while for roofs and floors it offers exceptional load-bearing capacity, thermal breaks, wind resistance, and energy performance. The flexibility of the panel system allows for customization to meet a wide range of design requirements, accommodating any type of cladding, sheathing, or insulation to ensure optimal performance for the intended application.

[0037] Another principal object and advantage of the present invention is designed not only to revolutionize construction but to create unparalleled opportunities for component manufacturers. Far from being a competitive threat, it is a platform that actively enhances the value of the materials and products already in the marketplace. Manufacturers of cladding, insulation, fasteners, sheathing, and other components should view the panels as a boon to their business an innovative system that elevates their products by seamlessly integrating them into a high-performance, cutting-edge panel solution.

[0038] Another principal object and advantage of the present invention is it eliminates thermal bridging by incorporating a continuous insulation layer. Closed-cell spray foam is applied directly onto the sheathing and studs with no thermal breaks, creating a thermal break that significantly enhances energy efficiency. This results in superior thermal performance with higher R-values per inch, reducing heating and cooling costs while promoting long-term energy savings.

[0039] Another principal object and advantage of the present invention is the panels are fully customizable, allowing for project-specific configurations while meeting all North American code compliance standards (ASTM, ANSI, ESA and AWP).

[0040] Another principal object and advantage of the present invention is it utilizes HFO-blown closed-cell foam with an impressively low Global Warming Potential (GWP~4), making it an environmentally responsible choice compared to traditional foam cores with higher GWPs. This innovation aligns with green building certifications and reduces the environmental impact of construction projects.

[0041] Another principal object and advantage of the present invention provides that construction doesn't have to be a logistics nightmare. Flat-packed panels are shipped to your site ready to assemble. No semi-trucks full of loose lumber, no stacks of insulation and no fighting to make everything fit.

[0042] Another principal object and advantage of the present invention provides that no on-site water resistant barrier (WRB) is Required. The panels come factory-sealed with integrated waterproofing layers, eliminating the need for additional water resistant barriers (WRB) during installation. This reduces labor costs, speeds up construction, and removes the risk of job-site errors in WRB application. The pre-installed WRB wraps over the panel edges securely attaches to the top, bottom and side plates, protecting the foam and OSB sheathing from exposure to the elements.

[0043] Another principal object and advantage of the present invention provides built-in peel-and-stick WRB. The panels feature pre-applied, fully adhered WRB membranes, ensuring airtight and watertight walls from day one. Unlike SIPs, which rely on exposed OSB edges that can rot when exposed to moisture, TSUPS™ panels eliminate weak points by integrating WRB at the factory level.

[0044] Another principal object and advantage is that the TSUPS panel of the present invention is a higher lateral load. Lateral loads are forces that act horizontally on a structure, perpendicular to its vertical axis. These forces come from wind, seismic activity, soil pressure, and external forces such as water movement. Unlike gravity loads, which act downward, lateral loads attempt to push or pull a structure sideways, which can lead to racking, overturning, or sliding if not properly resisted. With a total shear capacity of 1,060 per linear foot (plf), the TSUPS panel nearly doubles the strength of a standard OSB shear wall and significantly outperforms SIPs. Chemically bonds to both the studs and sheathing creates a composite structural effect that distributes forces more evenly. This makes it an ideal choice for hurricane-prone, high-wind, and seismic areas, offering a balance of superior structural stability, energy efficiency, and durability. With a total shear capacity of 1,060 plf, the TSUPS panel nearly doubles the strength of a standard OSB shear wall and significantly outperforms SIPs. This makes it an ideal choice for hurricane-prone, high-wind, and seismic areas offering a balance of superior structural stability, energy efficiency, and durability.Comparisons to Other Wall Structures are Illustrated Below:

[0045] Another principal object and advantage is that the TSUPS panel of the present invention is it has no thermal bridging occurs where heat flows more easily through highly conductive materials within a building's envelope, bypassing the insulation. This typically happens where structural elements like wood studs, metal framing, or concrete interrupt the continuous insulation layer. These areas create pathways for heat to escape in the winter and heat to enter in the summer, reducing overall thermal performance. Challenges created by thermal bridging in energy-efficient homes includes increased heat loss and gain. Winter: Heat escapes through framing, increasing heating demand. Summer: Heat enters through the same paths, increasing cooling loads. This leads to higher energy consumption, reduced occupant comfort and reduced insulation effectiveness.

[0046] Even with high-R-value insulation, thermal bridges (fasteners, wall construction components, concrete and lumber) reduce overall wall performance.Average House in AmericaWall TypeThermal Bridging (%)Traditional Stick-Built (2 × 6 + OSB)25%SIPs (EPS Core)10%TSUPS Panel (100% Thermally Broken) 0%BRIEF DESCRIPTION OF THE DRAWINGS

[0047] FIGS. 1A and 1B are prior art views of the inventor's Composite Reinforced Studs, commonly referred to as Bare Naked Tstuds;

[0048] FIGS. 2A and 2B are prior art views of the inventor's Composite Foamed Reinforced Studs, commonly referred to as R19 Studs;

[0049] FIGS. 3A and 3B are prior art views of the inventor's Outboard Foamed Studs, commonly referred to as Warm Studs;

[0050] FIGS. 4A and 4B are prior art views of the inventor's Double S-Shaped Foamed Metal Studs with foam therearound commonly referred to as Rhino Studs;

[0051] FIGS. 5A, 5B and 5C are prior art views of the inventor's Offset Joined Twin Studs;

[0052] FIGS. 6A and 6B are prior art views of the inventor's Drain Strips with open honeycombed core and bug / pest screen to be horizontally or vertically mounted on exterior sheathing;

[0053] FIG. 7 is a front perspective view of the present invention referred to as the Thermal Studs Ultimate Panel System with top, bottom and side plates (TSUPS);

[0054] FIG. 8 is a top perspective view of the present invention with the top plate removed for ease of viewing the construction of the inner panel to include from left to right a Offset Joined Twin Studs, a Double S-Shaped Foamed Metal Stud, Composite Reinforced Stud, a Composite Foamed Reinforced Stud, an Outboard foamed stud, and a conventional stud.

[0055] FIG. 9 is a top perspective view of the present invention with the top plate removed for ease of viewing the construction of the inner panel to include the Double S-Shaped Foamed Metal Studs;

[0056] FIG. 10 is a top perspective view of the present invention with the top plate removed for ease of viewing the construction of the inner panel to include the Composite Foamed Reinforced Studs on the left and the Composite Reinforced Stud on the right;

[0057] FIG. 11 is a top perspective view of the present invention with the top plate removed for ease of viewing the construction of the inner panel to include 2×4″, 2×6″, 2×8″, 2×10″ and 2×12″ Outboard Foamed Studs;

[0058] FIG. 12 is a top perspective view of the present invention with the top plate removed for ease of viewing the construction of the inner panel to include 2×4″, 2×6″, 2×8″, 2×10″ and 2×12″ conventional studs;

[0059] FIG. 13 is a perspective view of the first framing table with loose unassembled lumber thereon;

[0060] FIG. 14 is a perspective view of the first framing table with an assembled panel frame being hooked up to an overhead crane for picking up the frame to be moved to the second foaming table;

[0061] FIG. 15 is a perspective view of the foaming second table with permanent right angle curb boards and sinusoidal heating elements thereunder;

[0062] FIG. 16 is a perspective view of the foaming table with permanent right angled curb boards and poly being laid over the table and a panel sheathing board placed on top of the poly on the foaming table and up against the curb boards;

[0063] FIG. 17 is a perspective view of the foaming table with permanent right angled curb boards and poly being laid over the table, a panel sheathing board (OSB) placed on top of the poly and on top of the foaming table to be moved against the curb boards and the crane delivering an assembled frame to the foaming table;

[0064] FIG. 18 is a perspective view of the crane with four cables horizontally picking up the assembled frame for delivery to the foaming table;

[0065] FIG. 19 is a perspective view of the foaming table with permanent right angled curb boards and poly being laid over the table, a panel sheathing board (OSB) placed on top of the foaming table up against the curb boards after the crane has delivered an assembled frame to the foaming table;

[0066] FIG. 20 is a perspective view of the foaming table with permanent right angled curb boards and poly being laid over the table, a panel sheathing board (OSB) placed on top of the poly and foaming table up against the curb boards. The assembled frame set in place on the foaming table where it is squared by horizontal corner equal measurements after which the frame is secured to both the permanent curbs and the temporary curbs (shown broken away for clarity) by clamps while be held in its elevated position by the crane (not shown for clarity of understanding) and the shown screws secure the frame to the curbs in perfectly squared condition ready for foaming;

[0067] FIGS. 21 and 22 and side elevational and perspective views explaining that the frames often have lumber that has bowing upwardly or downwardly. In the present invention the boards that have bowing are face down into the foam void space to allow the curing foam to accommodate for bowing resulting in complete flat inner and outer surfaces. The frame is further held down in place and top flush with the curb boards by a guillotine arrangement including pivot yokes, guillotine hold down boards which are pivotally held in place by yokes and are held down in place by pinning to the pin down yokes;

[0068] Referring to FIG. 23 is a perspective view that shows a foaming table with a spry foaming robot for spraying foam into the unfinished panel;

[0069] Referring to FIG. 24 is a perspective view that shows a foaming table with an operator spray foaming foam into the unfinished panel;

[0070] FIG. 25 is a perspective view that shows that the foam can be poured into the frame;

[0071] FIG. 26 is a perspective view that additionally shows a cured foam recyclable piece of foam 35 may be ground up and reused in the foam to be sprayed.

[0072] FIG. 27 is a perspective view that shows the crane about to pick up the foamed frame;

[0073] FIG. 28 is a perspective view that shows the robotic arm picking up the foamed frame;

[0074] FIG. 29 is a perspective view that shows the crane flipping over the panel onto finished third table;

[0075] FIG. 30 is a perspective view that shows the water resistive barrier WRB being dispensed over the panel. The WRB is any material or system applied to a building's exterior substrate to prevent bulk water intrusion while allowing controlled vapor diffusion. WRBs enhance durability, weather protection, and energy efficiency by providing a continuous moisture barrier behind the cladding. Self-Adhered WRBs (Peel-and-Stick Membranes) are made from rubberized asphalt, butyl, or modified bitumen, laminated to polyethylene or polypropylene films. An example is Henry Blueskin VP100—a vapor-permeable butyl-based membrane with a high-strength backing;

[0076] FIG. 31 is a perspective view that shows the WRB side of the panel wrapping over the sheathing and the top, bottom and side plates;

[0077] FIG. 32 is a perspective view that showing the horizontal drain strips underneath the vertical cladding;

[0078] FIG. 33 is a perspective view that showing the vertical drain strips underneath the horizontal cladding;

[0079] FIG. 34 is a perspective view that shows the mechanical joining of two side by side panels with screw or nails with rubber foam between the side plates for sealing engagement;

[0080] FIG. 35 is a perspective view that shows the joined two panels;

[0081] FIG. 36 is a perspective view that shows two corner panels joined together by screws;

[0082] FIG. 37 is a perspective view that show the building and the building site partially assembled;

[0083] FIG. 38 is a perspective view that show the outside of the building and the building site partially assembled;

[0084] FIG. 39 is a perspective view that shows that insulation batting may further fill the panel over the sprayed foam, if desirable by the builder;

[0085] FIGS. 40A, 40B and 40C are side elevational views that shows the panel in a floor application; and

[0086] FIG. 41 is a perspective view that shows the panel in a roof application.DETAILED SPECIFICATION

[0087] Referring to FIG. 7, the thermal Stud foamed panel for buildings, or commonly called the Thermal Studs Ultimate Panel System (TSUPS) 70 may be generally understood as illustrated. The Panel 70 includes an inner surface 71 to be facing the inside the future building and an outer surface 72 to be facing the outside environment. The panel 70 has a frame 73 comprised of 2×6″ studs 74, 2×6″ sill, top and bottom plates 76 and panel side plates 78.

[0088] The frame 73 is spaced from an outer layer of sheathing, OSB or plywood 80 that is dimensioned to match the length and width dimensions of the sheathing 80. Curable liquid foam 82 is introduced partially around and internally of the frame 70 and continuously between the equally dimensioned frame 70 and sheathing 80 without any thermal breaks between the frame 70 and the sheathing 80. Once the foam 82 has cured, the foam 82 adhesively secures and bonds the frame 70 and sheathing 80 together.

[0089] A water resistant barrier WRB 84 is adhesively secured to the sheathing 80, top, bottom and side plates 76, 78 of the panel 70. A Water Resistant Barrier WRB 180 is any material or system applied to a building's exterior substrate to prevent bulk water intrusion while allowing controlled vapor diffusion. WRBs enhance durability, weather protection, and energy efficiency by providing a continuous moisture barrier behind the cladding.

[0090] Referring to FIG. 8, a top plate 76 is removed to show the interior construction of the panel frame 73. Panel 70 is capable of being built with a variety of stud discussed in the above Background to include a composite reinforced stud 10, a composite foamed reinforced stud 20, an outbound foamed stud 30, a double S-shaped foamed metal stud 40, offset joined twin studs 50, 52, and 54 and conventional studs 56. All these studs may be 2×4″, 2×6″, 2×8″, 2×10″ or 2×12″ in depth. Again, all of these studs 10, 20, 30, 40, 50, and 56 are spaced ¾″ to 3.5″ from the sheathing 80 and this void is filled with sprayed in foam 82 at least partially up the sides of the studs.

[0091] Referring to FIG. 9, the shown panel 70 is built with double S-shaped foamed studs 40 with conduit holes 42 therethrough for temporary or permanent insertion of an insulative conduit 44 through which wiring 46 or plumbing may pass through.

[0092] Referring to FIG. 10, the shown panel 70 is built with composite foamed reinforced stud 20 to the left and with composite reinforced stud 10 on the right.

[0093] Referring to FIG. 11, the shown panel 70 is built with a outboard foamed studs 30 which may be 2×4″, 2×6″, 2×8″, 2×10″ or 2×12″ in depth.

[0094] Referring to FIG. 12, the shown panel 70 is built with conventional studs 56 which may be 2×4″, 2×6″, 2×8″, 2×10″ or 2×12″ in depth.

[0095] Referring to FIG. 13, a framing first table 90 is shown with loose lumber 92 thereon for assembly and securement together with screws or framing ring nails.

[0096] Referring to FIG. 14, an assembled frame 73 is shown with eyelets 104 on the framing table 90 hooked up to cables 102 connected to the crane or winch 100 above for moving the assembled frame 73 to the foaming table 120.

[0097] Referring to FIG. 15, the foaming second table 120 is shown with a heat conducting metal top plate 122 with heating coils 126 therebelow mounted to the table 120 with spacers 122 as to not overheat the wood therebelow. The heating coils heat the foam 82 to facilitate even curing and maximum rise of the foam 82. Visible are right angled 90° (arrow A) permanently secured and aligned curb boards 128, 130 with holes or apertures 132 threw which screws secure the frame 73 to the squared curb boards128, 130 for squaring the frame 73.

[0098] Referring to FIG. 16, the foaming second table 120 is shown with polyethylene 134 laid over the table to prevent overflow of liquid sprayed foam 82 onto the table 120, beyond the sheathing 136 or curb boards 128, 130. Polyethylene or lumber wrap is typically made from woven polyethylene (PE) or polypropylene (PP) fabric with a UV-resistant coating. These materials provide durability, moisture resistance, and protection against sun exposure during transportation and storage. The material is strong and tear-resistant and reuseable and any cured sprayed foam that touched the poly 134 will not permanently stick to the poly 134.

[0099] Thereafter, the sheathing 136 is placed on the table 120 and snugged up to the squared curb boards 128, 130.

[0100] Referring to FIG. 17, the crane 100 has delivered the assembled frame 73 to the foaming second table 120 from the framing first table 90.

[0101] Referring to FIG. 18, the crane 100 with four cables 102 is shown ready to pick up the assembled frame 73 on the framing table 90 for delivery to the foaming table 120.

[0102] Referring to the FIG. 19, the assembled frame 73, with its eyelets 104 removed, is ready to be located over the equally dimensioned sheathing 80, 136.

[0103] Referring to FIG. 20, the crane 100 (not shown) could be used to levitate the frame 73 exactly over the same dimensioned sheathing 80, 136 by approximately ¾″ to 3½″, which is generally the desired thickness of the cured sprayed foam 82. After the frame 73 is squared with diagonal measurements, clamps 140 can be secured between the frame 73, the permanent curb boards 128, 130 and the temporary curb boards 131.

[0104] Referring to FIGS. 21 and 22, the frames often have lumber that has bowing upwardly or downwardly. In the present invention the boards that have bowing are face down into the foam void space to allow the curing foam to accommodate for bowing resulting in complete flat inner and outer surfaces. The frame 73 is further held down in place and top flush with the curb boards 128, 130 and 131 by a guillotine arrangement including pivot yokes 146, guillotine hold down boards 148 which are pivotally held in place by yokes 146 and are held in place by pinning to the pin down yokes 150.

[0105] Referring to FIG. 23 shows a foaming table with a spray foaming robot 160 for spraying foam 34 into the unfinished panel 120.

[0106] Referring to FIG. 24 shows a foaming table with a spry foaming operator for spraying foam 34 into the unfinished panel 120.

[0107] FIG. 25 shows that the foam 34 can be poured into the frame 73.

[0108] FIG. 26 additional shows a cured foam recyclable piece of foam 35 may be ground up and reused in the foam 73 to be sprayed.

[0109] FIG. 27 shows the crane 100 picking up the foamed frame 73 off the foaming table 120.

[0110] FIG. 28 shows the robotic arm 164 picking up the foamed frame 73.

[0111] FIG. 29 shows the crane 100 flipping over the panel 10 onto finished third table 178.

[0112] FIG. 30 shows the water resistive barrier 180 WRB being dispensed over the panel 10. The WRB is any material or system applied to a building's exterior substrate to prevent bulk water intrusion while allowing controlled vapor diffusion. WRBs enhance durability, weather protection, and energy efficiency by providing a continuous moisture barrier behind the cladding. Self-Adhered WRBs (Peel-and-Stick Membranes) are made from rubberized asphalt, butyl, or modified bitumen, laminated to polyethylene or polypropylene films. An example is Henry Blueskin VP100—a vapor-permeable butyl-based membrane with a high-strength backing.

[0113] FIG. 31 shows the WRB side of the panel 10 wrapping over the sheathing 80 and the top,

[0114] FIG. 32 is showing the horizontal drain strips 60 underneath the vertical cladding.

[0115] Referring to FIG. 33 shows the vertical drain strips 60 underneath the horizontal cladding.

[0116] Referring to FIG. 34 shows the mechanical joining of two side by side panels 10 with screw or nails 186 with rubber foam between the side plates 78 for sealing engagement.

[0117] FIG. 35 shows the joined two panels 10.

[0118] FIG. 36 shows two corner panels 10 joined together by screws 186.

[0119] FIG. 37 shows an interior wall of a building partially assembled.

[0120] FIG. 37 shows that insulation batting may further fill the panel 10, if desirable by the builder.

[0121] FIG. 38 is showing the horizontal drain strips 60 underneath the vertical cladding.

[0122] FIG. 39 shows a top view of panel 10 with batt insulation 188 filling in over the cured sprayed foam 82.

[0123] FIG. 40 shows the panel in a floor application.

[0124] FIG. 41 shows the panel in a roof application.

Claims

1. A completely insulated building, wall, roof and floor panel each with inner and outer surfaces that have no thermal bridging between the inner and outer surfaces of the panels, comprising:a. construction of the panel each include a wall, roof or floor wood or metal frame with top, bottom and side plates;b the frame is spaced from an outer layer of sheathing that is dimensioned to match the length and width dimensions of the sheathing;c. curable liquid foam is introduced partially around and internally of the frame and continuously between the equally dimensioned frame and sheathing without any thermal breaks between the frame and the sheathing; andd. a water resistive barrier is adhesively secured to the sheathing, top, bottom and side plates of the panel.

2. A method of manufacturing a completely insulated building, wall, roof or floor panel each with inner and outer surfaces that have no thermal bridging between the inner and outer surfaces of the panels, comprising:a. constructing a frame with top, bottom and side plates with internal parallel vertical studs having a width and a length;b placing a sheathing board having the width and length equal to the width and the length frame on top of a poly film on a foaming table, the poly having a width and length enough to cover the sheathing board and the top, bottom and side plates of the frame;c. suspending the frame directly over and away from the sheathing board creating a void between the frame and the sheathing board;d. placing liquid curable polyurethane foam into the void and touching the internal parallel vertical studs and the top, bottom and side plates;e. allowing the foam to cure; andf. adhering a water resistive barrier over the sheathing board and the top, bottom and side plates of the frame.

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