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

• US 6,796,093 B2
• Filed: 03/18/2002
• Issued: 09/28/2004
• Est. Priority Date: 03/18/2002
• Status: Expired due to Fees

• Current Assignee: Candor Development Incorporated
• Original Assignee: Donald J. Brandes
• Inventors: Brandes, Donald J.
• Primary Examiner(s): Friedman, Carl D.
• Assistant Examiner(s): SLACK, NAOKO N
• Application Number:
  US10/101,549
• Publication Number:
  US 20030172607A1
• Time in Patent Office: 925 Days
• Field of Search: 523/097, 523/098, 523/091.4, 523/091.6, 523/091.3, 524/073, 524/811, 527/62, 527/451.9, 527/295, 527/831, 527/841.2, 527/841.3, 527/841.5, 527/921, 528/001.2
• US Class Current: 52/309.8
• CPC Class Codes: E04B 1/24 the supporting parts consisting of metal
• CPC Class Codes: E04B 2/7412 Posts or frame members specially adapted for reduced sound or heat transmission
• CPC Class Codes: E04B 2001/2463 Connections to foundations
• CPC Class Codes: E04B 2001/2466 Details of the elongated load-supporting parts
• CPC Class Codes: E04B 2001/2481 Details of wall panels
• CPC Class Codes: E04B 2001/249 Structures with a sloping roof
• CPC Class Codes: E04C 2/205 of foamed plastics, or of plastics and foamed plastics, optionally reinforced
• CPC Class Codes: E04C 2/384 with a metal frame

Abstract

A structural panel for a building structure includes first and second stud members each including a neck. Openings and venturi bridges are formed in the neck. At least one flange is attached to the neck. A foam panel extends between the studs. The openings in the neck limit the heat transferred from the stud to the edge of the foam panel. The venturi bridges in the neck also limit the transfer of heat from the neck to the edge of the foam panel.

Claims

1. A method of producing a structural panel for a building, including the steps of

(a) providing at least first and second stud members each comprising an elongate member including

(i) a neck having

a selected thickness,

a front,

a back,

a first elongate side, and

a second elongate side, and

(ii) at least one flange outwardly projecting from one of said sides of said neck,

 

each of said stud members being 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; and

,

(b) providing a foam panel having

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,

(c) positioning said foam panel intermediate said first and second metal stud members such that

(i) a portion of said first side extends between said inside face and said outside face and adjacent said front of said first stud member to form a first structural and thermal transmission interface,

(ii) one of said edges of said first side is adjacent said front of said first stud member,

(iii) a portion of said first side extends away from said first stud member,

(iv) the other of said edges of said first side is spaced apart from said first stud member,

(v) a portion of said second side extends between said inside face and said outside face and adjacent said back of said second stud member to form a second structural and thermal transmission interface,

(vi) one of said edges of said second side is adjacent said back of said second stud member,

(vii) a portion of said second side extends away from said second stud member; and

(viii) the other of said edges of said second side is spaced apart from said second stud member;

(d) placing a structural member along the other of said edges of said second side; and

,

(e) interconnecting said structural member and said second stud with a plurality of spaced apart support members each having a first end connected to said structural member and a second end connected to said second stud;

said method including the steps of

(a) forming a plurality of openings through said neck of at least said first stud member intermediate said first and second elongate sides and having a cumulative cross-sectional area and a cumulative area normal to said cross-sectional area; and

,

(b) forming a plurality of venturi bridges in at least said neck of said first stud member, each bridge being adjacent at least one of said openings and extending from said first elongate side to said second elongate side of said stud, said venturi bridges having

a cumulative cross-sectional area less that the cross-sectional area of said plurality of openings, and

a cumulative surface area on said front of said neck,

a cumulative surface area on said back of said neck,

 

such that the ratio of the portion of said surface area of said first edge to said cumulative surface area of said venturi bridges on said front of said neck of said first stud is in the range of 25;

1 to 4;

1 to limit the transmission of heat from said first stud to the portion of said first edge extending from said openings in said first stud and said venturi bridges in said first stud to said inside face of said foam panel.