# US 2020/0399899 A1 · Structural insulated panel framing system > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2020/0399899 A1 - Document ID: US20200399899A1 - Status: Published application - Kind: A1 - Application number: 17/009,642 - Filed: 2020-09-01 - Published: 2020-12-24 - Earliest claimed: 2012-05-18 - Assignees: Nexgen Framing Solutions LLC - Applicants: Nexgen Framing Solutions LLC - Inventors: Clifton D. Singleton; Zonnie C. Singleton - Web page: https://patentgrep.com/patent/US20200399899A1 ## CPC - E04C 2/284: at least one of the materials being insulating - E04B 1/7604: {fillings for cavity walls} - E04B 1/7654: {comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings} - E04B 2/58: with elongated members of metal - E04C 2/384: {with a metal frame} - E04C 2/46: {specially adapted for making walls (E04C2/52, E04C2/54 take precedence; structure of slab-shaped elements E04B1/02; walls of elements of relatively thin form E04B2/72)} - E04C 2/521: {serving for locating conduits; for ventilating, heating or cooling} - G06F 30/13: Architectural design, e.g. computer-aided architectural design [CAAD] related to design of buildings, bridges, landscapes, production plants or roads - E04C 2002/3488: {spaced apart by frame like structures} - E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S) - E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001}) - G06F: ELECTRIC DIGITAL DATA PROCESSING (computer systems based on specific computational models G06N) ## Abstract Systems and methods are disclosed herein to a structural insulated panel framing system comprising: insulation sheathing receivable by a wall jig; a frame for placement atop the insulation sheathing; and spray foam for application to the frame and the insulation sheathing to fuse the frame and insulation sheathing to produce a structural insulated panel. ## Claims ### Claim 1 A framing system comprising: an structural insulated panel, comprising: an insulation sheathing; a frame comprising a top plate, a bottom plate, a pair of outer studs, and an inner stud, wherein the pair of outer studs and the inner stud span between the top plate and the bottom plate, wherein each of the outer studs and inner stud has a proximal side and a distal side, wherein the inner stud is positioned between the pair of outer studs; a mesh coupled to the insulation sheathing, wherein each of the distal sides of the outer studs and the distal side of the inner stud abuts the mesh; and a cured spray foam adhering the insulation sheathing and the mesh to the frame such that the insulation sheathing, the mesh and the frame are unitary, wherein the insulation sheathing and the mesh are coupled to the frame without mechanical fasteners. ### Claim 2 (depends on 1) The framing system of claim 1, wherein the insulation sheathing is a first insulation sheathing, and wherein the proximal sides of the outer studs and the proximal side of the inner stud are configured to abut a second sheathing. ### Claim 3 (depends on 1) The framing system of claim 1, wherein the frame includes at least one of a framing member, a brace, and a blocking, wherein the at least one of the framing member, the brace, and the blocking is configured to receive at least one of a rivet and a screw. ### Claim 4 (depends on 1) The framing system of claim 1, wherein the insulation sheathing comprises expanded polystyrene. ### Claim 5 (depends on 2) The framing system of claim 2, wherein the mesh is interposed between the insulation sheathing and the frame. ### Claim 6 (depends on 1) The framing system of claim 1, wherein the spray foam comprises a closed cell spray foam. ### Claim 7 A method, comprising: positioning an insulation sheathing on a wall jig; positioning a frame on the wall jig in alignment with the insulation sheathing; dispensing spray foam within the frame and onto the frame and the insulation sheathing; and fusing the insulation sheathing to the frame using the spray foam to produce a unitary structural insulated panel, wherein the insulation sheathing is coupled to the frame without mechanical fasteners. ### Claim 8 (depends on 7) The method of claim 7, further comprising: generating a map for forming the frame from frame components using a software application. ### Claim 9 (depends on 8) The method of claim 8, further comprising: forming the frame components using a roll former according to the map created by the software application; and assembling the frame components to form the frame. ### Claim 10 (depends on 7) The method of claim 7, further comprising: applying a mesh to a first side of the insulation sheathing before placing the frame on the wall jig, wherein the first side of the insulation sheathing faces the frame. ### Claim 11 (depends on 10) The method of claim 10, further comprising: cutting the insulation sheathing and the mesh so that the insulation sheathing and armor mesh match the dimensions and configuration of the frame. ### Claim 12 (depends on 7) The method of claim 7, further comprising: inserting a pipe through pre-cut holes in the frame so that the pipe extends through the structural insulated panel. ### Claim 13 (depends on 7) The method of claim 7, further comprising: locking the frame and the insulation sheathing to the wall jig using a vertical tie bar that clamps into the wall jig and a locking mechanism that locks a horizontal spacer bar to the wall jig. ### Claim 14 (depends on 7) The method of claim 7, wherein the spray foam is a closed cell spray foam. ### Claim 15 (depends on 14) The method of claim 14, further comprising: spraying an open cell spray foam within cavities of the structural insulated panel that are not filled by the closed cell spray foam, the insulated sheathing, or the frame. ### Claim 16 A structural insulated panel, comprising: an insulation sheathing; a frame comprising a top plate, a bottom plate, a pair of outer studs, and an inner stud, wherein the pair of outer studs and the inner stud span between the top plate and the bottom plate, wherein each of the outer studs and inner stud has a proximal side and a distal side, wherein each of the distal sides of the outer studs and the distal side of the inner stud abuts the insulation sheathing, wherein the inner stud is positioned between the pair of outer studs; and a spray foam sprayed within cavities of the frame such that the spray foam substantially covers internal surfaces of the cavities and fuses the frame to the insulation sheathing when cured such that the insulation sheathing and the frame are unitary, wherein the insulation sheathing is coupled to the frame without mechanical fasteners. ### Claim 17 (depends on 16) The structural insulated panel of claim 16, further comprising a mesh in contact with the spray foam, wherein each of the distal sides of the outer studs and the distal side of the inner stud abuts the mesh such that the insulation sheathing, the frame, and the mesh are unitary. ### Claim 18 (depends on 16) The structural insulated panel of claim 16, wherein the insulated sheathing comprises an expanded polystyrene. ### Claim 19 (depends on 16) The structural insulated panel of claim 16, wherein the spray foam is a closed cell spray foam. ### Claim 20 (depends on 19) The structural insulated panel of claim 19, wherein a density of the closed cell spray foam is at least 1.8 pounds per cubic foot. ### Claim 21 (depends on 19) The structural insulated panel of claim 19, further comprising: an open cell spray foam filling the cavities of the frame. ### Claim 22 (depends on 21) The structural insulated panel of claim 21, wherein the open cell spray foam has a density of 0.5 pounds per cubic foot or less. ### Claim 23 (depends on 1) The framing system of claim 1, wherein the mesh is a first mesh, wherein the structural insulated panel further comprises a second mesh, wherein the first mesh contacts the spray foam such that the insulation sheathing, the frame, and the first mesh are unitary, wherein the insulation sheathing is interposed between the first mesh and the second mesh. ### Claim 24 (depends on 1) The framing system of claim 1, further comprising: a wall jig; a tie bar removably coupled to the wall jig, wherein the wall jig supports the insulation sheathing and the frame, wherein the tie bar secures at least one of the insulation sheathing and the frame to the wall jig. ### Claim 25 (depends on 1) The framing system of claim 1, further comprising: a wall jig; a spacer bar removably coupled to the wall jig, wherein the wall jig supports the insulation sheathing and the frame, wherein the spacer bar secures the frame to the wall jig. ### Claim 26 (depends on 25) The framing system of claim 25, further comprising: a removable locking mechanism coupled to the wall jig, wherein the locking mechanism locks the spacer bar against the frame. ### Claim 27 (depends on 1) The framing system of claim 1, further comprising: a wall jig; a tie bar removably coupled to the wall jig; a spacer bar coupled to the wall jig, wherein the wall jig supports the insulation sheathing and the frame, wherein the tie bar secures at least one of the insulation sheathing and the frame to the wall jig, wherein the spacer bar secures the frame to the wall jig. ### Claim 28 (depends on 27) The framing system of claim 27, further comprising: a locking mechanism coupled to the wall jig, wherein the locking mechanism locks the spacer bar against the frame. ### Claim 29 (depends on 17) The structural insulated panel of claim 17, wherein the mesh is interposed between and abuts the insulated sheathing and the frame. ### Claim 30 (depends on 16) The structural insulated panel of claim 16, further comprising: a first mesh abutting the frame and contacting the spray foam such that the spray foam fuses the first mesh to the frame and the insulation sheathing when cured such that insulation sheathing, the frame, and the first mesh are unitary, a second mesh coupled to the insulation sheathing such that the insulation sheathing is interposed between the first mesh and the second mesh. ### Claim 31 (depends on 16) The structural insulated panel of claim 16, wherein the insulation sheathing is a first insulation sheathing, and wherein the proximal sides of the outer studs and the proximal side of the inner stud are configured to abut a second sheathing. ### Claim 32 (depends on 1) The structural insulated panel of claim 1, further comprising an appliance extending through the inner stud and the outer studs via a hole through each pair of open ends such that the appliance is positioned between the top plate and the bottom plate. ### Claim 33 (depends on 32) The structural insulated panel of claim 32, wherein the appliance is coated with a release agent that prevents adhesion of spray foam, such that the appliance is removable. ### Claim 34 (depends on 1) The structural insulated panel of claim 1, wherein the inner stud and the outer studs comprise an open shaped structure. ### Claim 35 (depends on 34) The structural insulated panel of claim 34, wherein the inner stud and the outer studs comprise steel. ### Claim 36 (depends on 34) The structural insulated panel of claim 34, wherein the open shaped structure is at least one of a C-shaped or I-shaped structure. ### Claim 37 (depends on 1) The framing system of claim 1, wherein the insulation sheathing and the mesh are coupled to the frame using only cured spray foam or adhesive. ### Claim 38 (depends on 1) The framing system of claim 1, wherein the insulation sheathing and the mesh are coupled to the frame using only cured spray foam. ### Claim 39 (depends on 16) The structural insulated panel of claim 16, wherein the insulation sheathing is coupled to the frame using only spray foam or adhesive. ### Claim 40 (depends on 16) The structural insulated panel of claim 16, wherein the insulation sheathing is coupled to the frame using only cured spray foam.