THERMAL TRANSFER BARRIER BUILDING MEMBERS

Abstract
Process for forming building members from a metal coil is described, where the members have a thermal barrier coating on at least one contact or exposed surface. Such building members and apparatus for continuously coating and forming the members are also described.
Description

BRIEF DESCRIPTION OF THE DRAWINGS


FIG. 1 schematically shows a metal substrate coated with multiple layers of thermal barrier coating.



FIG. 2 show cross-sectional profiles of three exemplary structural members useful in the present invention that are typically formed by roll forming: A. Z-member, B. C-member, C. U-member (e.g., a track).



FIG. 3 shows cross-sectional profiles of three exemplary roofing panels, an exemplary wall stiffener section, and an exemplary floor deck section that are typically formed by roll forming: A. standing seam roofing, B. simple corrugated roofing, C. spaced rib roofing, D. wall stiffener, and E. floor decking.



FIG. 4 shows an exemplary roll formed emergency egress opening frame illustrating placement of a peripheral thermal barrier coating.



FIG. 5 schematically shows different locations on a steel framed building where use of thermal barrier coated structural members provides an advantageous thermal barrier.



FIG. 6 illustrates a simplified version of a combined roll forming and thermal barrier coating line. A. top view, B. side view.



FIG. 7 illustrates a simplified version of a thermal barrier coating system that includes an uncoiler, a sprayer that can spray bands of coating on one or both faces of a metal coil, and a re-coiler. A. top view, B. side view.



FIG. 8 illustrates a simplified version of a thermal barrier coating systems that includes an uncoiler, a coating bath, e.g., a hot dip bath, and a re-coiler. A. top view, B. side view.



FIG. 9 shows a cross-section of a portion of a sandwich panel having thermal barrier coatings on the exterior surfaces and a foam core.


Claims
  • 1. A process for preparing a building member, comprising unwinding a metal coil of a particular thickness;coating at least a longitudinal band of said metal coil with a thermal barrier coating to provide a coated sheet; androll-forming a building member from said coated sheet, wherein the coating is present on at least one contact surface of said building member.
  • 2. The process of claim 1, wherein said coating is performed before said roll-forming.
  • 3. The process of claim 1, wherein said roll-forming is performed before said coating.
  • 4-7. (canceled)
  • 8. The process of claim 1, wherein said thermal barrier coating is a paint.
  • 9. (canceled)
  • 10. The process of claim 1, wherein said thermal barrier coating is a metal coating.
  • 11-15. (canceled)
  • 16. The process of claim 1, further comprising applying at least a second coating of thermal barrier material following said roll-forming.
  • 17. (canceled)
  • 18. The process of claim 1, wherein said building member is a wall stud.
  • 19-27. (canceled)
  • 28. The process of claim 1, wherein said thermal barrier coating comprises a thermal barrier permanent metal coating and a thermal barrier paint coating.
  • 29. A process for finishing a metal coil, comprising coating at least a longitudinal band of a metal strip of a particular thickness with a thermal barrier coating; andfollowing said coating, coiling said metal strip as a coated metal coil.
  • 30-32. (canceled)
  • 33. The process of claim 29, wherein said thermal barrier coating is a thermal barrier paint.
  • 34. (canceled)
  • 35. The process of claim 29, wherein said thermal barrier coating is a permanent metal coating.
  • 36-39. (canceled)
  • 40. A process for making a building member, comprising forming a thermal barrier coated meal coil of a particular thickness into a building member.
  • 41. The process of claim 40, wherein said forming comprises roll-forming.
  • 42. The process of claim 40, wherein said forming comprises stamping.
  • 43. (canceled)
  • 44. The process of claim 40, wherein the thermal barrier coating on said metal coil comprises a thermal barrier paint coating.
  • 45. The process of claim 40, wherein the thermal barrier coating on said metal coil comprises a thermal barrier metal coating.
  • 46-60. (canceled)
  • 61. A thermal barrier coated metal coil, comprising a coil of metal sheet, wherein said sheet comprises at least a longitudinal band coated on at least one side with a thermal barrier coating.
  • 62. (canceled)
  • 63. (canceled)
  • 64. The thermal barrier coated metal coil of claim 61, wherein said longitudinal band is coated on both sides.
  • 65. (canceled)
  • 66. The thermal barrier coated metal coil of claim 61, wherein said thermal barrier coating comprises a thermal barrier paint.
  • 67. The thermal barrier coated metal coil of claim 61, wherein said thermal barrier coating comprises a thermal barrier metal coating.
  • 68. (canceled)
  • 69. (canceled)
  • 70. A formed metal building member, wherein said member comprises a thermal barrier coating on at least one surface.
  • 71. The building member of claim 70, wherein said member is roll-formed.
  • 72. (canceled)
  • 73. (canceled)
  • 74. The building member of claim 70, wherein said thermal barrier coating comprises a paint.
  • 75. (canceled)
  • 76. The building member of claim 70, wherein said thermal barrier coating comprises a metal coating.
  • 77. (canceled)
  • 78. The building member of claim 70, wherein said thermal barrier coating comprises hollow microspheres.
  • 79. (canceled)
  • 80. The metal building member of claim 70, wherein said building member is a structural member and said surface is a contact surface.
  • 81. (canceled)
  • 82. The building member of claim 80, wherein said member is a stud.
  • 83-99. (canceled)
  • 100. A thermal barrier steel wall stud, comprising a longitudinal member, wherein said member comprises a web and two peripheral flanges, wherein said peripheral flanges are coated on their outer surfaces with a thermal barrier coating.
  • 101-116. (canceled)
  • 117. A steel coil processing system, comprising a coil handling mechanism;a coating reservoir containing a thermal barrier coating material, anda thermal barrier coating system, wherein said thermal barrier coating material is applied to said steel coil.
  • 118-132. (canceled)
Provisional Applications (2)
Number Date Country
60863798 Oct 2006 US
60781428 Mar 2006 US