Building panel with a rigid foam core, stud channels, and without thermal bridging

• US 8,109,058 B2
• Filed: 06/18/2008
• Issued: 02/07/2012
• Est. Priority Date: 10/05/2006
• Status: Expired due to Fees

• Current Assignee: Funform LLC
• Original Assignee: Kenneth Andrew Miller
• Inventors: Miller, Kenneth Andrew
• Primary Examiner(s): Safavi, Michael
• Application Number:
  US12/214,343
• Publication Number:
  US 20080250740A1
• Time in Patent Office: 1,329 Days
• Field of Search: 523/092, 523/097, 522/69, 522/67, 522/65, 522/207
• US Class Current: 52/309.7
• CPC Class Codes: E04B 1/14 the elements being composed of two or more materials of reinforced concrete E04B1/04
• CPC Class Codes: E04B 1/80 slab-shaped
• CPC Class Codes: E04C 2/22 reinforced E04C2/205 takes precedence
• CPC Class Codes: E04C 2/384 with a metal frame

Abstract

A structural insulated panel includes a rigid foam core without thermal bridging. A particular embodiment includes a rigid foam core having first and second faces, a plurality of stud channels being formed on the first and second faces of the rigid foam core, each of the stud channels being formed in the rigid foam core in an L-shape in cross-section. The particular embodiment includes a plurality of studs being insertable into the plurality of stud channels such that one face of each of the plurality of studs being external to the first and second faces of the rigid foam core and substantially flush with a face of the rigid foam core, each of the plurality of studs being fabricated using no more than four bends to produce a stud with a hat channel shape in cross-section.

Claims

1. A load-bearing building apparatus comprising:

a rigid foam core having first and second faces, a plurality of stud channels being formed vertically on the first and second faces of the rigid foam core, each of the stud channels being formed in the rigid foam core as voids in an L-shape in cross-section, each of the stud channels being formed by cutting L-shape channels into the rigid foam core thereby enabling slideable insertion of a stud into a void of each L-shape channel, the stud having an L-shaped structure corresponding to the L-shape channel, the stud channels being formed without removing a portion of the rigid foam core between the L-shape channels, each of the stud channels including a lubricating adhesive having been applied thereto, the lubricating adhesive including a lubricating agent to facilitate sliding the stud into the voids of each stud channel, the lubricating adhesive including a bonding agent to lock the stud into each stud channel; and

a plurality of studs being slideable into the voids provided by the plurality of stud channels such that one face of each of the plurality of studs being external to either the first or second face of the rigid foam core and substantially flush with either the first or second face of the rigid foam core, each of the plurality of studs being fabricated using no more than four bends and each of the plurality of studs having an L-shaped structure corresponding to the L-shape channel, wherein each of the plurality of studs has a hat channel shape in cross-section, and wherein opposing studs of the plurality of studs are not coupled using a structural member running through the rigid foam core and creating a thermal bridge, the plurality of studs providing a vertical load carrying capacity for the load-bearing building apparatus, at least one face of the rigid foam core being curved.

2. The load-bearing building apparatus as claimed in claim 1 including a notched angle brace attached between the plurality of studs in a substantially perpendicular direction relative to the plurality of studs.