US 7,574,837 B2 · Insulated stud panel and method of making such

Abstract

A stud panel and method of making a stud panel where interior sheathing may be a temporary piece of transparent plastic or a permanent panel of sheet rock so as to retain insulation in place and minimize scarfing. The stud panel may include studs having through holes extending in a length direction of the stud panel such that insulation in adjacent inner regions separated by such studs interlock with each other and contribute to a structural integrity of the stud panel. The stud panel may include a space between inner studs and one of the exterior and interior sheathing so as to provide a thermal and sound break between the exterior and inner sheathing so as to minimize heat, air and sound transfer between the exterior and interior sheathing. A method of making the stud panel is further disclosed, where such a method may include the step of incrementally introducing insulation from a closed end of an inner region to an open end of an inner region and may further include the step of automatically introducing insulation into the inner regions of the stud panel.

A method of making a prefabricated stud panel, with the stud panel comprising i) a first plate;

ii) a second plate;
iii) exterior sheathing, with the exterior sheathing having an inner face;
iv) interior sheathing, with the interior sheathing having an inner face;
v) a set of studs between the first and second plates and further between the exterior and interior sheathing, wherein the set of studs includes a pair of outer studs, wherein the set of studs includes a set of inner studs disposed inwardly of the outer studs, wherein each of the studs includes a width running in a direction from the exterior sheathing to the interior sheathing, and wherein the set of studs define a set of inner regions, with each of the inner regions being an area between one pair of adjacent studs, between the first and second plate of said one pair of adjacent studs, and between the exterior and interior sheathing of said one pair of adjacent studs;
vi) and wherein the stud panel includes a height direction defined by a direction between the first and second plates, a length direction defined by a direction between the outer studs, and a width direction defined by a direction between the exterior and interior sheathing;
with said method of making a stud panel comprising the steps of:
a) building a frame comprising the first and second plates, the outer studs, and the inner studs;
b) engaging one of the exterior and interior sheathing on a first face of said frame such that a second face of the frame is an open face;
c) introducing cellular polymer insulation into the frame such that cellular polymer insulation is introduced into at least one inner region;
and then
d) engaging the other of the exterior and interior sheathing on the second face of the frame to close off the open face and form the prefabricated stud panel;
e) with at least one of the inner studs having a width less than a width between the inner faces of the exterior and interior sheathing such that a thermal break space is provided between said inner stud and one of the exterior and interior sheathing, with said step of introducing cellular polymer insulation into the frame comprising the step of introducing cellular polymer insulation into the thermal break space such that cellular polymer insulation in one inner region communicates with cellular polymer insulation in an adjacent inner region and such that a thermal break is provided via said inner stud extending incompletely between the exterior and interior sheathing;
and
f) wherein the step of introducing cellular polymer insulation into the frame includes the steps of introducing cellular polymer insulation into the frame to the first face of the frame and subsequently introducing cellular polymer insulation to generally a rough plane terminating short of the second face of the frame, wherein the rough plane and the second face are generally parallel to each other and such that an air space is formed between the rough plane, where the cellular polymer insulation terminates, and the second face where sheathing will be engaged.

11 more elements

Facts

Application

11/396,315Filed 30 Mar 2006 · division

Priority

6 Jun 2003

Published

US 2006/0260267 A123 Nov 2006

Granted

18 Aug 2009

Term ends

Not estimatedThe source records don’t support an estimate.

Classification12 codes

E04C 2/386
With attached ribs, flanges, or the like, e.g. framed panels: with a frame of unreconstituted or laminated wood
B29C 44/186
Filling preformed cavities: filling multiple cavities
E04B 1/7604
Specifically with respect to heat only: fillings for cavity walls
E04B 2/707
With supporting function: obturation by means of panels

Family

Application60/476,774Us provisional application · filed 6 Jun 2003

Application10/860,882Parent of this continuation-in-part · filed 4 Jun 2004

Application11/004,056Parent of this division · filed 3 Dec 2004

US 2006/0260267 A1Pre-grant publication · published 23 Nov 2006

US 7,168,216 B2Parent of this division

US 7,127,856 B2Parent of this continuation-in-part

Application11/004,056Parent of this continuation-in-part

US 2005/0055973 A1Published application

US 2005/0188649 A1Published application

US 7,574,837 B2This patent

From the US filing history. Foreign family members aren’t listed.

Insulated stud panel and method of making such

Life of this patent

Insulated stud panel and method of making such

Life of this patent

Abstract

Claims17