Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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CONSTRUCTION FRAMING MEMBER WITH INTEGRATED
THERMAL BREAK AND METHOD FOR MANUFACTURING SAME
Field of the Invention:
The present invention relates to building construction materials, and more
particularly to
construction materials with enhanced insulative properties.
Background of the Invention:
Improvements in building construction materials and methods are constantly
sought to enhance
the comfort and economy of residential and commercial buildings.
One of the arcas in which a large amount of effort is currently concentrated
is in the development
of alternate materials and construction methods to increase energy efficiency.
Heating a building
is negatively impacted if the building is not properly sealed and insulated;
gaps in the structure of
the building as well as thin, non-insulated walls allow heat to transfer out
of the building and
increase heating costs, as well as result in uneven heating levels within the
building.
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In addition to the increased cost of energy for heating the building, there is
also undue damage to
the environment due to the increased amounts of heating fuel or energy which
are consumed to
keep these buildings at comfortable temperatures. As such it is desirable to
provide or enhance
the effect of insulation in the walls of buildings to prevent or minimize heat
loss.
Typical walls of a building are manufactured with dimensional lumber or other
stud materials,
having a gypsum or other type of wall board on the interior of the building.
Vapor barrier may
also be used between the interior wall surface and the studs or dimensional
framing members
which provide structure to the wall in the building. The studs act as an inner
member framework
which, along with providing structure and support for the wall itself, also
support wall coverings,
windows and doors. They also provide mounting cavities or mounting surfaces
for electrical
wiring, plumbing. HVAC systems and other utilities.
Standard dimensional lumber or other aluminum or steel stud materials are
often used to
construct these walls. Most often interior walls are generally constructed
with 2 inch x 4 inch
wall studs, although sometimes 2 inch x 6 inch wall studs would be used to
provide more
strength. Typically the studs or framing members are placed a predefined
standard spacing apart,
for example either every 16 or 24 inches. Extra studs can be used or provided
wherever walls
intersect, or to provide a nailing area or additional support.
Batts of insulation would typically be installed in the spaces between framing
members inside a
wall to provide insulation and reduce heat loss through the cavities between
the framing
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members. To the exterior of a building wall there is often an air barrier and
some kind of an
exterior surface or siding which is attached through to the studs.
Insulation batts are important in providing insulation in the areas of the
cavities between the
framing members. Some common forms of insulation hafts are made from
fiberglass, mineral
wool, or cotton. These batts are fibrous sheets that arc long and wide enough
to fit snugly
between wall studs. Another form of insulation is loose-fill insulation, which
is a light fibrous
fill. This type of insulation is laborious to install and typically requires a
professional installer.
Furthermore, this type of insulation is easily affected by air movement. There
is also spray-
applied insulation that can fill cavities very well, but again, must be
applied by a specialized
contractor.
An effective insulation system will prevent the movement of air through the
system. If there are
any cavities, they will be filled with insulation, leaving no gaps in or
around the insulation. The
structural members in the wall oftentimes act as thermal bridges, extending
from the warm side
of the insulation to the cold side of the insulation, allowing for an easy
escape of heat. While
insulation batts installed in the cavities between the framing members provide
some insulation to
a building, the framing members or studs of the wall allow heat transfer to
occur from the warm
side to the cool side of the wall through the framing members themselves. This
problem is
further emphasized with the use of metal member portions instead of wood,
because much more
heat flows through metal studs and joists than through pieces of wood.
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There have been many attempts to prevent heat loss through thermal bridges
such as the framing
members. One of the most popular methods of preventing this type of heat loss
is to provide
some type of rigid, board-stock insulation on the exterior face of the studs,
usually expanded
polystyrene or insulation batts. However, installation of this type of
insulation on all the exterior
faces of the studs involves wrapping the entire house with a rigid foam batt,
or similar type of
insulation product, which is very expensive and labour intensive. Again, this
type of material
can also be an irritant or hazardous during installation and will often
require professional
installation.
Another attempt to minimize this type of heat loss is to space the wall studs
at 24 inches apart,
rather than 16 inches apart. This extra spacing between the studs reduces the
total number of
studs in the wall, thus reducing the surface area of the framing members
available for heat
transfer. I lowever, the reduction in the number of total framing members
reduces the strength of
the wall. As such, it is not desirable to reduce the number of framing
members, if possible.
Furthermore, the reduction in framing members does not eliminate, or even
minimize, the heat
loss that will occur through the remaining framing members.
A further attempt to minimize heat loss through wall studs uses a method of
staggering the wall
studs that appear next to one another. A first wall stud would be situated
against the inner wall
leaving a gap between the first wall stud and the outer wall, and a second
wall stud adjacent the
first wall stud would be situated against the outer wall leaving a gap between
the second wall
stud and the inner wall, whereby the wall studs would alternate positions as
such along the wall.
In this way, a given stud will not concurrently contact the materials of the
inner wall and the
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materials of the outer wall, and will consequently be unable to transfer heat
directly from the
inner wall, through to the stud, to the outer wall and out of the building.
However, there are
many drawbacks associated with this method, as well. This method of reducing
heat loss
through studs is very labor intensive and expensive, as each stud needs to be
perfectly placed in
relation to the studs next to it. This furthermore increases the thickness of
the wall and reduces
the strength of the wall since each of the inner wall and the outer wall are
only provided with one
half of the number of wall studs for support.
What is needed, therefore, is a construction framing member that has enhanced
thermal
insulative properties but is capable of manufacture using relatively simple
methods that do not
introduce undue complexity.
Summary of the Invention
The present invention seeks to provide a construction framing member that
comprises standard
material but incorporates a thermal break in the form of an insulative
material.
According to a first aspect of the present invention there is provided a
framing member for use in
the manufacture of a construction framing member, the framing member including
a channel for
receiving insulative material. The framing member is preferably composed of
wood and the
channel is preferably a channel running substantially the length of the
framing member and
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exposed at the surface of the framing member at one edge thereof, and
extending through the
majority of the thickness of the member.
According to a second aspect of the present invention there is provided a
construction framing
member that comprises a framing member comprising a channel, and an insulative
material
situate in the channel. The insulative material has a lower thermal
conductivity than the framing
member which houses it and therefore increases the thermal insulation
properties of the
construction framing member.
According to a third aspect of the present invention there is provided a
method of manufacturing
a framing member comprising the steps of: (a) providing a length of wood
suitable to be used as
a framing member, the length of wood having a depth; (b) providing a wood-
cutting tool having
a cutting implement with an operative length less than the depth: and (c)
cutting a channel in the
length of wood in the direction of the depth using the cutting implement to
form the framing
member, such that the channel penetrates into the length of wood to less than
the depth. The
wood-cutting tool may be a table saw or router or any other similar tool known
in the art, and the
cutting implement would then be a blade or bit or similar cutting implement,
respectively, which
can be set to a length that is less than the depth, such that when the cutting
of the channel is
completed a portion of wood still remains intact beyond the set reach of the
cutting implement.
There could also be a purpose built machine for this purpose, which would cut
the channel in the
wood and then in a following step place insulative material in the channel (by
rolling a rolled
insulation into the channel, foaming a ply insulation into place or the like).
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According to a fourth aspect of the present invention there is provided a
method of
manufacturing a construction framing member comprising the steps of: (a)
providing a length of
wood suitable to be used as a framing member, the length of wood having a
depth; (b) providing
a wood-cutting tool having a cutting implement with an operative length less
than the depth; (c)
cutting a channel in the length of wood in the direction of the depth using
the cutting implement
to form a framing member, such that the channel penetrates into the length of
wood to less than
the depth; (d) providing an insulative material; and (e) introducing the
insulative material into the
channel to form the construction framing member. The insulative material may
be either a solid
component sized to fit in and preferably fill the channel, or a foam or other
liquid insulative
material that can be injected into the channel to fill the channel, wherein
upon solidification of
the insulative material in the channel the construction framing member is
formed.
Brief Description of the Drawings:
While the invention is claimed in the concluding portions hereof, preferred
embodiments are
provided in the accompanying detailed description which may be best understood
in conjunction
with the accompanying diagrams where like parts in each of the several
diagrams are labeled
with like numerals, and where:
Figure la is a perspective view of a framing member in accordance with the
present
invention:
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Figure lb is a top plan view of the framing member of Figure I a;
Figure 1 c is a side elevation view of the framing member of Figure la;
Figure 2 is a perspective view of a construction framing member according to
the present
invention; and
Figure 3 is a flow chart showing the steps of one embodiment of the method of
manufacture of the construction framing member of the present invention.
The present invention will now be described with reference to the accompanying
drawings of
illustrated embodiments.
Detailed Description of Illustrated Embodiments:
The following discussion provides many example embodiments of the inventive
subject matter.
Although each embodiment represents a single combination of inventive
elements, the inventive
subject matter is considered to include all possible combinations of the
disclosed elements.
Generally speaking, the inventive concept consists of the placement of an
insulated thermal
break into a dimensional construction framing member. The insulation provides
a thermal break
in assembled walls using the member, while providing some rigidity and
structural integrity to
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the member as well. By placing the insulation in a channel that extends
through most but not all
of the depth of the member, streamlined manufacturing options are presented,
resulting in
enhanced economy and a novel improvement over the prior art.
Referring now in detail to Figures la to lc, a framing member 10 according to
the present
invention is illustrated. The framing member 10 is a construction framing
member 34, as will
be described below. The framing member 10 comprises a channel 12 which in the
exemplary
embodiment extends the length of the framing member 10; it will he clear to
one skilled in the art
that the channel 12 need not extend the entire length of the framing member 10
in order to
enhance the insulative properties of the framing member 10, but having a
relatively continuous
channel 12 along the entire length will optimize such properties and
streamline manufacturing.
This channel 12 is for the receipt of insulative material 32, as will be
described below. The
framing member 10 is preferably composed of wood, due to the ease with which
the channel 12
can be cut out of a wooden substrate and the utility of wooden framing members
in construction
contexts.
The framing member 10 comprises a first section 14 and a second section 16,
separated by the
channel 12 which extends inwardly from the outer surface 30 of the framing
member 10. As the
channel 12 does not pass completely through the framing member 10, a thin
remainder of
material connects the first and second sections 14, 16, namely the connecting
section 18. The
channel 12 is therefore only exposed in the exemplary embodiment at the outer
surface 30 and
opposed first and second ends 26, 28 of the framing member 10.
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The channel 12 is preferably a channel running substantially the length of the
framing member
and exposed at the outer surface 30 of the framing member 10, and it is
defined by the inner
surface 20 of the first section 14, the inner surface 22 of the second section
16 and the inner
surface 24 of the connecting section 18.
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Turning now to Figure 2, a construction framing member 34 according to the
present invention is
illustrated. The construction framing member comprises the framing member 10,
with an
insulative material 32 disposed within the channel 12. In this way, the
original dimensions of the
lumber are maintained but with the presence of a thermal break incorporated
within the
10 construction framing member 34 to enhance the insulative properties of
the building material.
The manufacture of a framing member 10 in accordance with the present
invention can be
accomplished using known tools and methods of woodworking. First, a length of
wood suitable
for use as a framing member is provided, and this may be a standard 2 inch x 4
inch or 2 inch x 6
inch piece of lumber that is commonly used in construction and therefore will
likely be of
suitable dimensions for the building plans. This length of wood will have a
standard depth, 2
inches in most cases. Next, a standard wood-cutting tool such as a table saw
or router table is
provided, the wood-cutting tool having a cutting implement. This cutting
implement (a saw
blade in the case of a table saw, or a router bit in the case of a router
table) can be set at a desired
height above the work surface of the tool, and in the case of a length of wood
having a depth of 2
inches the desired cutting implement height setting is preferably
approximately 1-3/4 inches,
although the height setting can be any length less than 2 inches. With the
operative height of the
cutting implement set at less than the depth of the piece of lumber, the user
then cuts a channel
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12 in the length of wood in the direction of the depth using the cutting
implement in a manner
well known to those skilled in the art, such that the channel 12 penetrates
into the length of wood
to less than the depth. When the cutting of the channel 12 is completed, a
portion of wood still
remains intact beyond the set reach of the cutting implement, specifically the
connecting section
18. The width of the channel 12 can vary as needed given the predetermined
insulative
properties that the final construction framing member is to have, and one
skilled in the art will
know how to use various wood-cutting tools to achieve channels 12 of varying
widths.
Whereas the insulative material 32 could be introduced in any number of ways,
including cutting
a piece of solid insulation to the size of the channel 12 and fixing it in
place (by glue or other
known means) between the first and second sections 14, 16. it is preferable to
use polyurethane
foam insulation as the insulative material 32 and inject same into the channel
12. Once the
injected foam insulation has hardened, the waste can be cut away such that the
outer surfaces of
the insulative material 32 are flush with the outer surface 30, first end 26
and second end 28 of
the framing member 10. The width of the insulative material 32 can be
generally between 1/2
inch and 1 inch, although the width could vary depending on the heat
conductivity of the
particular insulative material 32 and the thickness required to obtain the
desired degree of
insulation. Where the construction framing member 34 is secured in place in a
wall, with the
first section 14 disposed toward the building interior and the second section
16 disposed toward
the outside of the building, heat transfer can be minimized from the first
section 14 of the
framing member 10 to the second section 16 of the framing member 10, thus
reducing the
thermal bridge between the inner wall and the outer wall of the building.
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It should also be noted that the above description is of one exemplary
embodiment only as
illustrated by the accompanying Figures, and the size of the first section 14,
second section 16
and insulative material 32 could each be adjusted for a number of reasons. For
example, the
insulative material 32 could be thickened or thinned based upon the particular
thermal
requirements of the application in which the construction framing member 34
when assembled
would be used. Also, the first and/or second sections 14,16 might be sized
appropriately such
that their utility in conventional construction techniques would be maximized,
e.g. such that
they would still most strongly support fasteners attached thereto, etc. In one
embodiment, the
complete construction framing member 34, including the first and second
sections 14, 16 plus the
integrated insulative material 32 could in total be approximately the same
size as a standard
dimensional framing member, for example in total being the approximate
dimensions of a
standard 2 inch x 4 inch or 2 inch x 6 inch framing member, such that it could
be easily
interchanged into pre-existing construction methods and market acceptance of
the product could
be maximized. It will be understood by one skilled in the art that there is no
specific ideal set of
dimensions for the construction framing member 34 of the present invention but
that any number
of different pre-existing dimensional lumber sizes could be duplicated using
the construction
framing member 34.
Figure 3 is a flow chart demonstrating the steps in one embodiment of the
method of
manufacture of the present invention. As outlined above, the base or substrate
for the
construction framing member of the present invention is a dimensional piece of
framing lumber,
which would be typically used in the production or manufacturable wall or
other structure
requiring the integration of the thermal break therein. The first step in the
method shown in this
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embodiment is to provide a cutting tool which could machine the channel 12 as
outlined
elsewhere herein into the substrate or framing member 34. In some cases this
could comprise a
table saw, a guided router or the like, or in other circumstances of purpose
built machine for the
manufacturer of the construction framing member of the present invention can
be provided
which was capable either in fixed or adjustable fashion of cutting the desired
channel into the
framing member or substrate, through some but not all of its depth, into which
insulating
material could be adhered. The cutting machine which would machine the channel
into the
framing member would include one or more guides common offenses or the like to
guide the
framing member in appropriate relation to the cutting tool for the formation
of the channel. Step
3-1 shows the provision of the cutting tool.
A framing member would be fed into and through the cutting tool, resulting in
the kind of a
channel into the framing member extending through the majority of the depth of
the framing
member along substantially all of its length, and across a portion of its
width. Cutting of the
channel into the framing member is shown at step 3-2.
Following the cutting of the channel into the framing member, shown at 3-2,
insulating material
would be placed and adhered into the channel, forming the thermal break in the
finished
construction framing member. The specific nature of this insulation placement
and adhesion step,
3-3, will depend upon the nature of the insulating material to be used. In
some cases channel may
be cut to the same size of precut or pre-manufactured insulating members which
could simply be
placed and glued into the channel, or in other cases rolled insulation could
be placed into the
channel and adhered. It is specifically contemplated that in some embodiments
of the method of
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manufacture, the insulating material which will be used would be foamed
polymeric insulation,
which could simply be injected into the channel as the framing member passed
out of the cutting
tool, such that it would expand to fill the channel and potentially be trimmed
or otherwise
cosmetically finished, to yield the finished construction framing member.
It is specifically contemplated that a machine for the practice of the
entirety of this method could
be developed in a circumstance where it was decided to produce large
quantities of the
construction framing member of the present invention, and any machine which
would
accomplish the steps of guiding a framing member through the cutting of the
channel therein,
and the subsequent placement and adhesion of insulating material within the
channel, is also
contemplated within the scope of the present invention. As can also be seen,
the manufacturer of
the product of the present invention could be done in a reasonably continuous
process
particularly where purpose built machine for the combined coming of the
channel and placement
and adhesion of the insulative material was produced, or a combination of
equipment was placed
in line to work in such a continuous feeding fashion. Again, any machine which
allowed for the
guided kind of a channel until framing member and the subsequent placement and
adhesion of an
insulated thermal break therein, otherwise in accordance with the remainder of
the present
invention outlined herein, is explicitly contemplated within the scope of the
present invention.
As can be readily seen, then, the framing member and construction framing
member of the
present invention present significant advantages over the prior art. Enhanced
thermal insulation
properties are provided in a product that can be manufactured in industry
standard sizes for case
of implementation. There is no need to implement a novel stud arrangement or
spacing that may
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weaken the structure, but rather the structural strength of wood is maintained
while integrating a
thermal break.
The foregoing is considered as illustrative only of the principles of the
invention. Thus, while
certain aspects and embodiments of the invention have been described, these
have been
presented by way of example only and are not intended to limit the scope of
the invention. It
will be apparent to those of skill in the art that by modification the present
invention can be
optimized for use in a wide range of conditions and applications. It will also
be obvious to those
of skill in the art that there are various ways and designs with which to
produce the apparatus and
methods of the present invention. The illustrated embodiments are therefore
not intended to
limit the scope of the invention, but to provide examples of the apparatus and
method to enable
those of skill in the art to appreciate the inventive concept.
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