WOOD BUILDING STUDS WITH AN OUTBOARD FOAM INSULATION THERMAL BARRIER AND METHOD OF MANUFACTURE

Abstract

A conventional dimensioned wood building board have an outbound edge that has been incised and with some crown remediation. An even outboard foam insulation barrier layer is applied to the incised outboard edge of the board. A method for manufacturing multiples of these insulated wood building boards in an assembly line includes compressing the crown out of the side outbound edge of the boards, incising the crown side edge of the boards, applying an even thickness layer of outbound foam insulation to keep the boards within the dimension of conventional lumber, separating the boards and sanding to finish the wood boards with outboard foam insulation.

Description

BACKGROUND OF THE INVENTION

The present invention relates to temporarily straightened wood building studs with a crown with an outboard foam insulation barrier that keeps the resultant insulated stud within the accepted dimensions of dimensional, structural or conventional studs (2×4″, 2×6″, 2×8″, 2×10″ and 2×12″). A method for manufacturing these wood building studs with an evenly-thick outbound foam insulation layer, includes compressing the crown out of the side edge of the stud, incising the crown side edge of the stud and applying an even layer of outbound foam insulation to keep the stud within the dimension of conventional lumber.

Standard construction today uses either 2×4″ or 2×6″ solid lumber generally spaced 16″ on center. Where energy conservation is a concern, most builders frame an exterior wall with 2×6's. Up to 28 percent of the exterior wall (studs, top and bottom plates, cripple studs, window/door jambs and headers and the rim area of the floor) is solid wood framing. Thermal bridges are points in the wall that allow heat and cold conduction to occur. Heat and cold follow the path of least resistance—through thermals bridges of solid wood across a temperature differential wherein the heat or cold is not interrupted by thermal insulation. The more volume of solid wood in a wall also reduces available insulation space, and further, the thermal efficiency of the wall suffers and the R value (resistance to conductive heat flow) decreases.

The most common way to minimize thermal bridging is to wrap the entire exterior of the building in rigid insulation to minimize heat loss and cold from entering the building. This effort significantly increases materials, carbon footprint and labor costs and can be undesirable in increasing the thickness of the building walls with non-structural materials.

Attempts have been made to construct framing systems with built in thermal breaks with the use of dimensional or conventional lumber (2×4″, 2×6″, 2×8″, 2×10″ and 2×12″). Such efforts require extensive labor and materials costs and have not resulted in completely effective thermal breaks or barriers throughout the whole wall, corners and building envelope structure.

Applicant has previously patented framing systems with near-complete thermal breaks throughout the walls, corners and building structures made of non-dimensional lumber with rigid insulation that has increased strength, more surface area for building materials to be fastened to, uses less lumber, has more space for insulation to greatly increase thermal efficiencies. Some of these U.S. utility patents are U.S. Pat. Nos. 9,667,264; 9,783,985 and 10,731,332.

A significant patentable feature of these patents include a wall core structure that includes a wall stud comprised of two spaced apart parallel boards or planks with mechanical fasteners therebetween of a structure of diagonally spaced, alternating angled wood dowels connecting the boards and surrounded with injected liquid rigid insulation, such as expanded polyurethane, polystyrene or polyisocyanurate. The foam 76 may suitably made by mixing an isocyanate, such as methylene diphenyl diisocyanate (MDI) with a polyol blend, or other suitable rigid foam sheet or there equivalent. In fact, it is to be anticipated that rigid foams of yet even higher R values are on the market now with more being created that are and will be suitable for use with the present invention. Polyurethane insulation has the highest thermal resistance (R-values) at a given thickness and lowest thermal conductivity. This stud design is currently being marked under the registered trademark TSTUD® by applicant's company Roosevelt Energy, Inc. of Ham Lake, Minnesota under Federal Registration Number 5,481,842.

More recently, applicant has been granted design patents of alternating or rotating the two boards with respect to each other with mechanical fasteners therebetween visually imitating a T-shape in cross section under U.S. Design Patents D941,496; D942,049; D941,498; D938,618 and D936,242.

As shown in prior art FIGS. 1, 2 and 3, conventional building lumber, wood boards or studs 3 have inherent twists or bows 5 in their faces 7 making them unsquared (dash lines). The boards 3 may also have crowns 9 on one side of the two edges which does not follow a true plane (dashed line). Twists 5 and crowns 11 are very much undesirable in building lumber 3 as they prevent complete securable abutment between lumber pieces 3 which has a deleterious effect on the integrity and strength of a building. Eight to 10% of severely warped boards are rejected for building structure usage. Boards with slight defects must be “untwisted”, “unbowed” and “uncrowned”. Nailing or screwing the mildly defective boards 3 into the building structure will help in “untwisting”, “unbowing” and “uncrowning” of the boards 3. Untreated crowns 11 also will not permit a dimensional even layer of foam to be applied to the outbound edge 9 and still maintain the stud within the dimension of conventional lumber.

In the context of woodworking and construction, “wane” refers to the presence of bark or the rounded, uneven edge of a board or timber. It occurs when the wood used for a stud or other structural element has not been properly squared or milled, leaving a portion of the outer surface of the tree, including bark and irregular contours, on one or more edges of the board.

Wane can weaken the structural integrity of the wood, as it may be more susceptible to splitting, cracking, or warping. In construction, it's important to avoid using lumber with excessive wane in load-bearing or structural applications, as it can compromise the strength of the material. Properly milled and squared lumber is typically preferred for such uses to ensure the stability and safety of the structure.

The allowable percentage of wane in a wood stud can vary depending on local building codes and regulations. However, a common guideline for construction is that wane should not exceed ⅓ of the width of the face of the stud. In other words, no more than one-third of the width of a stud can have wane.

For example, if you have a 2×4 stud (which is actually 1.5 inches by 3.5 inches in nominal dimensions), the wane on one face of the stud should not extend across more than ⅓ of the 3.5-inch width, which would be roughly 1.17 inches. This guideline is aimed at ensuring the structural integrity and strength of the stud. It's important to check your local building codes and regulations for any specific requirements in your area, as they may vary.

Wood building studs 3 with an outboard foam insulation barrier 17, as disclosed in Wirth Patent Application Publication Number 2010/0236172, most generally do not have an even dimensional thickness and often do not have a strong attachment or bond to the board 3 at outbound edge 11 as the foam 17 may fall off if bumped or torn off in transporting, handling and/or installing of the building studs 3. This weak bonding may be caused by the board being dirty, too smooth, wet or frozen when the when the foam 17 is affixed to the outbound edge 9 of lumber 3.

There is a need for dimensional lumber with a secure, evenly foamed outboard edge surface forming a thermal barrier between the lumber and exterior layer which greatly increases thermal efficiencies while reducing building costs, labor, energy usage and time to build such structures.

SUMMARY OF THE INVENTION

A conventional dimensioned wood building board have an outbound edge that has been incised and with some crown remediation. An even outboard foam insulation barrier layer is applied to the incised outboard edge of the board. A method for manufacturing multiples of these insulated wood building boards in an assembly line includes compressing the crown out of the side outbound edge of the boards, incising the crown side edge of the boards, applying an even thickness layer of outbound foam insulation to keep the boards within the dimension of conventional lumber, separating the boards and sanding to finish the wood boards with outboard foam insulation.

Principal object and advantage is to temporarily straightened wood building studs with a crown and securely bonding an even outboard foam insulation barrier on the incised studs' crown side edge that keeps the resultant insulated stud within the accepted dimensions of dimensional or conventional studs (2×4″, 2×6″, 2×8″, 2×10″ and 2×12″). An example would be a 2×4″ stud becomes 2×6″ with addition of an even 2″ layer of foamed insulation. A suitable range of foam insulation maybe 1½ to 2½″ where desirable or necessary to accommodate wane.

Another object and advantage of the present invention is that foamed insulation layer being in the range of 1½″ to 2½″ of liquid foam applied to make the next sized traditional stud. Adding 2″ to a 2×4 that is 3½″ deep makes the new product 5½″ deep which is a dimensional 2×6. Adding 1¾″ to a 5½″ 2×6 makes it 7¼″ which is a 2×8 dimensional lumber size.

Another object and advantage of the present invention is that foamed insulation layer is securely bonded to the outboard crowned side edge of the stud by incising the edge without damaging the wood fibers before adding the foamed insulation layer.

Another object and advantage of the present invention is that the R value of a 2×6 is increased from 6.8 to 17.7 and the R value of a 2×8 is increased from 9 to 18.5.

Another object and advantage of the present invention is that the nearer the R value of the stud to the R value of the cavity insulation, the potential of condensation is greatly diminished.

Another object and advantage of the present invention is that the invention has a smaller carbon footprint than standard building construction simply by use of less materials and labor costs.

Another object and advantage of the present invention is that there is more insulation in the wall cavity with less solid wood to increase thermal efficiency.

Another object and advantage of the present invention is that there could be a reduction in the needed and required sizing for furnaces and air conditioning equipment.

Another object and advantage of the present invention is that all these objects and advantages are accomplished without losing any integrity in building performance or structural qualities.

Another object and advantage of the present invention is that there will be a reduction on the future utility grid and a reduction on the future carbon footprint required to produce the electricity and gas to heat and cool a home or a building built to according to this invention.

Another object and advantage of the present invention is that the buyers of houses made in accordance to the present invention will be affordable and not exceed 30% of income and thereby not be an excessive burden according to the U.S. Department of Housing and Urban development (HUD).

Another object and advantage of the present invention is that in manufacturing the boards and foaming plenum, the boards and foaming plenum are heating to around 100° F. to minimize the amount of liquid foam that is used to insulate the stud with a reduction of liquid foam of about 20%.

Another object and advantage of the present invention is that if there is wane on the outer edge of the lumber, such will get filled in and makes the final board square thereby lending full support for the exterior sheathing.

Another object and advantage of the present invention is that 2×4 studs are supposed to be 3½″ but might vary to 3⅜″ or maybe 3⅝″. Also 2×6 studs are supposed to be 5½″ but might vary to 5⅜″ or maybe 5 9/16″. The liquid foam will accommodate to respectively make the studs 3½″ and 5½″ exactly to simplify building construction.

Another object and advantage of the present invention is that the R value of a 2×6 is increased from 6.8 to 17.7 and the R value of a 2×8 is increased from 9 to 18.5, thereby increasing the R value of the stud to as near as the cavity insulation to minimize condensation growth.

Another object and advantage of the present invention is that the present invention has an improved racking strength up to 684 pounds per square foot of wind force.

Another advantage is the ability to have a 100% complete thermal break through the entire wall assembly when using a metal or a wood “let in” brace to solve for additional racking strength.

Another advantage is the ability of the invention is to use the invention's stud for the bottom chord of a roof truss to create a thermal break through the entire roof assembly.

Another advantage is the ability of the invention to be used for the top chord of a roof truss to have a thermal break on the furthermost surface of the building envelop minimizing the suns effect on heating up the attic space.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a prior art perspective view of 2×4, 2×6, 2×8 2×10 and 2×12 inch dimensional or conventional lumber;

FIG. 2 is a prior art perspective view of dimensional lumber or a board showing undesirable twists, warps or bows.

FIG. 3 is a prior art side elevational view of dimensional lumber or a board showing an undesirable crown in one of the board's edges.

FIG. 4 is an invention perspective view of 2×4, 2×6, 2×8, 2×10 and 2×12 inch dimensional or conventional lumber with incising along the crowned, proposed outboard side edge;

FIGS. 5a and 5b are an enlarged elevational views partially broken away of various incising along the crowned side outbound edge;

FIG. 6 is a perspective view of the invention made with 2×4, 2×6, 2×8, 2×10 and 2×12 inch dimensional or conventional lumber, studs or boards with a 1½″ to 2½″ (ideally 1½″) foamed layer of outboard foam insulation barrier bonded onto the incised, proposed outboard edge that keeps the resultant insulated stud within the accepted dimensions of dimensional or conventional studs (2×6″, 2×8″, 2×10″, 2×12″ and 2×14″) of the present invention;

FIG. 7 is a perspective view of partially built wall structure made with the present invention boards with the foamed out bound edge facing outside and a sheathing panel fastened to the foamed edge of the boards on the outside of the wall and dry wall fastened to the inside of the wall;

FIG. 8a is a top plan schematic view of the assembly line of the present invention for simultaneously making multiple foamed studs or boards on an inline assembly line or machine with multiple stations to complete the manufacture of multiple foamed boards in quick fashion;

FIG. 8b is a side elevational view of the two part clam shell mold sections on upper and lower tank track-continuous belts;

FIG. 8c is a perspective view of two segmented mold sections wherein the upper and lower clams shells are together the two part urethane is being injected onto the boards in the mold plenum or foaming jig;

FIG. 8d is a cross sectional view taken along lines 8d-8d of FIG. 8c;

FIG. 8e is a perspective view of the urethane saw station after which the boards are separated; and

FIG. 8f is a top plan view of the sanding station.

DETAILED SPECIFICATION

Referring to FIGS. 1, 2 and 3, dimensional wood studs 3 for construction of building structures are typically made from pine, fur or spruce in sizes, 2×4 inches, 2×6 inches, 2×8 inches, 2×10 inches and 2×12 inches. Each stud typically has an outboard crowned surface 11 between the stud and the outer building surface layer. FIGS. 2 and 3 illustrate wood studs typically have some severe twist, warps, bows and crowns.

Boards 3 with severe twist, warps, bows and crowns are set aside and further not considered for use in building framing. To add an insulation quality to the lumber, boards or studs 12 that are not severely deformed, care must be taken that the present boards 12 are not too dirty, too smooth, wet or frozen when the when the foam 17 is affixed to the outbound edge 9 of lumber 3.

To further insure a strong bond between the foam or insulation barrier 17, the outbound board edge 9 of the board and the foaming plenum or cavity 61 are both heated to about 100° F. By so doing this, the ideal rate of chemical reaction and viscosity is achieved. Another inventive technique here to insure strong bonding is to incise the board outbound edge surface 9 as shown in FIGS. 4, 5a and 5b. However, care must be taken to not damage the wood fibers. Approximately ⅛ inch deep incisions are generally ideal as such will not damage the wood fibers. Both pin hole 13 and dash 15 incising insure the liquid foam disburses into these little holes or divots to allow the foam to embed into the increased edge 9 surface area of wood to form a strong bond of a 1½ inch by 1½ inch layer of foamed insulation barrier 17.

FIG. 7 illustrates the completed wood building studs 25 with outboard foam 17 forming a thermal barrier use in building a wall 21. The outbound side of the studs 25 have outside sheathing 27 nailed or screwed to the studs 25 passing through the insulation barrier 17. On the inside of the building wall 21, dry wall 29 may be fastened thereto.

FIG. 8a shows a top plan schematic-like view of a manufacturing line 40 for making boards with outboard formed insulation 25. The assembly line 40 generally includes at the beginning a roller convey belt 42 that is vertically secured to withstand vertical pressures from above. At this location is the board placement station 44. Next is the crown removing vertical compression roller station 46 and the boards are then horizontally clamped together by rollers 48 to hold the boards vertically in place. Thereafter the boards 12 are fed into the infrared heater station 56. Next following, the heated boards 12 have their outboard edges 9 incised at the incision roller station 58. From there, the boards 9 are fed into urethane injection station 60 and mold station 61 with upper and lower segmented, two part, track driven clam shells 64, 66 where the two part urethane molding materials 70, 72 are confined into the head space above the boards in the mold station 61. As the boards are passed into the mold station 61, the expanding urethane under compression begins to harden. After the boards 25 are foamed with the compressed cured urethane on top, they go to the urethane saw station 100 after which the boards 25 are separated and pass through the sanding station 110.

FIG. 8b is a right side elevational view of the mold station 61. The top left mold clam shell segments 64 are each connected by pivoting brackets 68 forming a continuous upper tank track-like drive belt 63 driven by sprockets 65 with the upper and left side clam shell mold sections 64 thereon.

FIG. 8b also shows the bottom right mold clam shell segments 66 are each connected by pivoting brackets forming a continuous lower tank track-like drive belt 67 driven by sprockets 69 with the lower right side clam shell mold sections 66 thereon. As the lower drive belt 67 rotates clockwise, the upper drive belt 63 rotates counter clockwise causing the upper clam shell section 64 and lower clam shell section 66 to come together on the left side to cover the incoming lumber 12 in a sealing arrangement and ready to start receiving the two part urethane mixture from the injection gun 78 as the lumber 12 moves along with the sealed together and joined clam shell sections 64, 66.

FIGS. 8c and 8d show the roller compression holding the sides of clam shell sections 64, 66 together under significant pressure by fixed horizontal compression wheels 82 up against the top left clam shell section 64 and opposing compression wheels 84 (see adjacent arrows). Simultaneously, the roller compression holding the top and bottom of clam shell sections 64, 66 together under significant pressure by fixed bottom compression wheels 86 up against the top left clam shell section 66 and opposing compression wheels 88 (see adjacent arrows). Dimpling 92 on the mold section plastic liners 90 assure to hold the boards 12 in place. The plastic liners 90, like the plastic/PVC/Nylon board spacers 45 assure that the urethane does not stick to any undesirable surfaces.

FIG. 8e shows the urethane saw station 100 with blades 102 driven by dimpled multiple driven rollers 104 to retain the straightness of the boards until they are released. The plastic spacers 45 between the urethaned boards 25 assure that the saw blades 102 do not touch, score or cut into the board faces 7 as the spacers 45 allow space for the blades should they go through the urethane 17. Any type of saw arrangement would work for this application.

Referring to FIGS. 8a and 8f, the sanding stations 110 with its drum sanders 112 driven by motors 114. The rough boards 40 with outboard insulation move on roller conveyor belt 42. By this arrangement, the rough boards 40 are sanded to square them up on top urethane 17 and side faces 7. The transitions from board to urethane after sanding is nice, smooth and square. Individual finished urethaned boards 25 may also be sanded on their faces 7 to complete the sanding process.

The above specification and accompanying FIGS. are for illustrative purposes only. The following claims form the bases and limitation of the present invention.

Claims

1. An insulated dimensional 2×6 inches, 2×8 inches, 2×10 inches, 2×12 or 2×14 inch wood boards made from dimensional 2×4 inch, 2×6 inch, 2×8 inch, 2×10 inch or 2×12 boards for walls, roofs and floors of houses and commercial buildings, the insulated stud comprising: a.) the outbound edge being incised to increase surface area thereof; andb.) a uniform 1½-2½ inch square liquid urethane foam insulation is bonded to the outboard incised thereby creating insulated dimensional lumber of 2×6 inches, 2×8 inches, 2×10 inches 2×12 inches or 2×14 inches.

2. The insulated dimensional wood boards of claim 1, wherein the outboard are incised up to ⅛ inches into the outboard edges as to not damage any wood fibers.

3. The insulated dimensional wood boards of claim 1, wherein the wood boards have their crowns mitigated by pressure force to assure the urethane foam insulation is uniform in 1½-2½ inch thickness.

4. The insulated dimensional wood boards of claim 1, wherein the wood boards are heated to approximately 100° F. to assure bonding of the urethane foam insulation and minimize the amount of liquid urethane foam used.

5. An assembly line for simultaneously manufacturing multiple evenly insulated dimensional boards of 2×6 inches, 2×8 inches, 2×10 inches 2×12 inches or 2×14 inches for walls, roofs and floors of houses and commercial buildings, comprising: a.) a board placement station for dimensional 2×4 inches, 2×6 inches, 2×8 inches, 2×10 inches or 2×12 inch wood boards with their outboard crowned edges facing upwards;b.) a vertical compression station for temporarily removing the crowns from the boards and hold the boards down once compressed;c.) an infrared heater station to warm the boards;d.) a two part urethane injection station followed immediately by a mold station to coat the boards and contain the expanding urethane under compression;e.) a urethane saw station to cut the urethane only and free the insulated dimensional boards; andf.) a sanding station to smoothly sand the boards with urethane thereon.

6. A method for simultaneously manufacturing multiple evenly insulated dimensional boards of 2×6 inches, 2×8 inches, 2×10 inches 2×12 inches or 2×14 inches for walls, roofs and floors of houses and commercial buildings, comprising: a.) stacking the boards face-to-face with the boards' outboard crowned edges facing upwards;b.) vertical compressing the outboard crowned edges downwardly temporarily removing the crowns from the boards and holding the boards down once compressed;c.) heating the boards to approximately 100° F.;d.) injecting two part urethane onto the outboard edges and passing the boards into a mold to guide and compress the curing urethane;e.) sawing the urethane parallel to the boards to separate the boards; andf.) sanding the urethane and boards to making the boards and urethane smooth.