MODULAR BRIDGELESS THERMAL ENVELOPE FOR PREFABRICATED CONSTRUCTION

Abstract

This application relates to methods of manufacturing a modular thermal envelope. The modular thermal envelope includes an internal structural frame. The modular thermal envelope further includes a non-structural insulated laminated wall panel. The modular thermal envelope further includes a bent clip. An example of a bent clip is a steel clip including a first portion welded to the structural interior frame element, a bent portion that defines a gap between the structural interior frame element, and a second portion of the bent clip. The modular thermal envelope has the non-structural insulated laminated wall panel positioned between the structural interior frame element and the second portion of the bent clip. The modular thermal envelope further is substantially weatherproof and airtight.

Claims

1. A modular thermal envelope comprising: an internal structural frame; a non-structural insulated laminated wall panel; a bent clip comprising: a first portion welded to the internal structural frame; a bent portion that defines a gap between the internal structural frame and a second portion of the bent clip, wherein the non-structural insulated laminated wall panel is positioned between the internal structural frame and the second portion of the bent clip; and wherein the modular thermal envelope is substantially weatherproof and airtight.

2. The modular thermal envelope of claim 1, wherein the internal structural frame is entirely contained within a boundary of the modular thermal envelope, the boundary of the modular thermal envelope comprising a continuous insulation layer.

3. The modular thermal envelope of claim 1, wherein the modular thermal envelope is thermally bridgeless.

4. The modular thermal envelope of claim 1, further comprising a roof clip comprising: a first section welded to the internal structural frame; an angled portion that defines a gap between the internal structural frame and the angled portion of the roof clip, wherein the angled portion is set at an angle of an architectural roof; and wherein a roof non-structural insulated laminated wall panel is positioned between the internal structural frame and the angled portion of the roof clip.

5. The modular thermal envelope of claim 1, wherein the non-structural insulated laminated wall panel comprises: a foam core; a plurality of gaps cut into a foam core of the non-structural insulated laminated wall panel; and an interior skin and an exterior skin to the foam core of the non-structural insulated laminated wall panel, wherein the interior skin is positioned on the foam core based on locations of the plurality of gaps.

6. A method of manufacturing a modular thermal envelope, the method of manufacturing comprising: forming an internal structural frame; assembling a non-structural insulated laminated wall panel; coupling the non-structural insulated laminated wall panel to the internal structural frame using a bent clip, the bent clip comprising: a first portion welded to the internal structural frame; and a bent portion that defines a gap between the internal structural frame and a second portion of the bent clip.

7. The method of manufacturing of claim 6, wherein forming the internal structural frame comprises containing the internal structural frame entirely within a boundary of the modular thermal envelope.

8. The method of manufacturing of claim 6, wherein the modular thermal envelope includes no thermal bridges between the internal structural frame and an exterior of the modular thermal envelope.

9. The method of manufacturing of claim 6, further comprising securing a roof non-structural insulated laminated wall panel to the internal structural frame, the securing comprising: forming a roof clip comprising: a first section welded to the internal structural frame; an angled portion that defines a gap between the internal structural frame and the angled portion of the roof clip, wherein the angled portion is set at an angle of an architectural roof; and positioning the roof non-structural insulated laminated wall panel between the internal structural frame and the angled portion of the roof clip.

10. The method of manufacturing of claim 6, wherein assembling a non-structural insulated laminated wall panel comprises: cutting a plurality of gaps into a foam core of the non-structural insulated laminated wall panel; and applying an interior skin and an exterior skin to the foam core of the non-structural insulated laminated wall panel, wherein the interior skin is applied to the foam core based on locations of the plurality of gaps.

11. A bridgeless thermal envelope comprising: an internal structural frame; a non-structural insulated laminated wall panel; a bent clip comprising: a first portion welded to the internal structural frame; a bent portion that defines a gap between the internal structural frame and a second portion of the bent clip; wherein the non-structural insulated laminated wall panel is positioned between the internal structural frame and the second portion of the bent clip; and wherein the bridgeless thermal envelope is substantially weatherproof and airtight.

12. The bridgeless thermal envelope of claim 11, wherein the internal structural frame is entirely contained within a boundary of the bridgeless thermal envelope, the boundary of the bridgeless thermal envelope comprising a continuous insulation layer.

13. The bridgeless thermal envelope of claim 11, further comprising a roof clip comprising: a first section welded to the internal structural frame; an angled portion that defines a gap between the internal structural frame and the angled portion of the roof clip, wherein the angled portion is set at an angle of an architectural roof; and wherein a roof non-structural insulated laminated wall panel is positioned between the internal structural frame and the angled portion of the roof clip.

14. The bridgeless thermal envelope of claim 11, wherein the non-structural insulated laminated wall panel comprises: a foam core; a plurality of gaps cut into a foam core of the non-structural insulated laminated wall panel; and an interior skin and an exterior skin to the foam core of the non-structural insulated laminated wall panel, wherein the interior skin is positioned on the foam core based on locations of the plurality of gaps.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] A further understanding of the nature and advantages of various embodiments may be realized by reference to the following figures. In the appended figures, similar components or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label by a dash and a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.

[0015] FIG. 1 illustrates a thermal envelope with an internal structural frame, according to exemplary embodiments of the present disclosure.

[0016] FIG. 2 illustrates component members of the internal structural frame, according to exemplary embodiments of the present disclosure.

[0017] FIG. 3 illustrates a sectional view of a thermal envelope with an internal structural frame, according to exemplary embodiments of the present disclosure.

[0018] FIG. 4, comprising FIG. 4A and FIG. 4B, illustrates sectional views of a roof and wall connection, according to exemplary embodiments of the present disclosure.

[0019] FIG. 5 illustrates a sectional view of a floor and wall connection of the thermal envelope, according to exemplary embodiments of the present disclosure.

[0020] FIG. 6, comprising FIG. 6A and FIG. 6B, illustrates sectional views of a junction between non-structural insulated laminated wall panels, according to exemplary embodiments of the present disclosure.

[0021] FIG. 7 illustrates a process of manufacturing a thermal envelope with an internal structural frame, according to exemplary embodiments of the present disclosure.

DETAILED DESCRIPTION

[0022] Briefly described, the present disclosure pertains to various configurations of a steel-framed modular unit framework clad with non-structural insulated laminated panels to achieve a finished wall, for the construction of building structures.

[0023] In a non-limiting example, a thermal envelope is created through assembly of a plurality of manufactured components. The thermal envelope includes a structural interior frame. The structural interior frame is enveloped by non-structural insulated laminated wall panels. In some embodiments, each NSIP is coupled to the structural interior frame by way of bent clips. An example of a bent clip is a steel clip including a first portion welded to the structural interior frame element, a bent portion that defines a gap between the structural interior frame element, and a second portion of the bent clip. The non-structural insulated laminated wall panel includes a recessed cutaway that is positioned between the structural interior frame element and the second portion of the bent clip, so as to fasten the NSIP to the structural interior frame. A sealing strip may be attached to the NSIP and positioned in the recessed cutaway to further seal the thermal envelope at the junction between two NSIPs. Examples of the sealing strip my include vapor tape, SIP tape, or the like.

[0024] As used herein, interior means facing towards the interior of the enclosed structure, horizontal means substantially parallel to a ground surface, vertical means substantially perpendicular to the ground surface, lateral means an orientation that is non-vertical and includes horizontal, exterior means facing towards the exterior of the thermal envelope.

[0025] Referring now to the figures, FIG. 1 illustrates a thermal envelope 100 with an internal structural frame, according to the present disclosure. An example of the thermal envelope 100 is a combination of wall panels, roof panels, floor panels that limit or prevent heat transfer from an interior section (e.g., inside the thermal envelope) to an exterior section (e.g., the outside of the thermal envelope) and vice versa.

[0026] As illustrated by FIG. 1, the thermal envelope 100 includes multiple non-structural insulated laminated wall panels 102, an insulated roof panel 106, additional wall panels 104, window panels 108, and an internal structural frame (obscured by the exterior skin of the various panels). It should be understood that additional wall panels 104 are of a similar design as non-structural insulated laminated wall panel 102, the additional wall panels 104 are modified for each thermal envelope to accommodate other features such as window panels, or other architectural features. The example shown in FIG. 1 does not show a door, but of course a door or some other entry way is provided in preferred embodiments and can be attached to the NSIP wall panels 102 in the same manner as window panels 108 are connected to NSIP wall panels 102. The interior structural frame, which is shown in and described in more detail with respect to other figures, is constructed in certain embodiments using a number of substantially horizontal and vertical beams to form an enclosure. An example of a non-structural insulated laminated wall panel 102 NSIP has an exterior panel and interior panel that sandwich an insulation layer. The interior and exterior panels may be finished with various types of laminates, or other veneer, etc. for aesthetic purposes. For clarity of explanation, the internal structural frame e.g., a steel frame as depicted in FIG. 2 bears the structural load of the thermal envelope 100 and the non-structural insulated laminated wall panel 102 bears only a transverse load, such as a wind force.

[0027] For example, the thermal envelope 100 is created by attaching one or more NSIPs to the exterior side of the beams comprising the internal structural frame. The NSIP preferably comprise a simplified 3-component system having an interior skin, rigid insulation, and exterior skin. In some instances, the internal structural frame is formed by metal, such as steel or any other sufficiently strong and preferably non-corrosive metal. The NSIP panels are attached to the metal frame using a series of bent clips (obscured in FIG. 1). The bent clips may be welded or otherwise fixedly secured to the outside, i.e., exterior side, of each of the horizontal, lateral or vertical beams of the internal structural frame (i.e. FIG. 2 showing the bent clips welded to the horizontal and lateral beams, providing a binding mechanism for the NSIPs to be removably attached to the internal structural frame. As explained below, a portion of the NSIP, formed by way of a recessed cut-away, is slid under the non-welded end of the bent clip, which provides a snug fit and leaves no gap that would allow outside air to penetrate the thermal envelope 100. Attaching the NSIPs to the internal structural frame such that each NSIP is exterior to the internal structural frame keeps the entirety of the internal structural frame inside of the thermal envelope 100. The configuration of the internal structural frame inside the thermal envelope increases airtightness, improves thermal efficiency, eliminates detrimental thermal bridges (e.g., fasteners penetrating the insulation of the thermal envelope), and reduces a potential for water condensation within the wall. The use of the bent clips improves assembly speeds and eliminates the need for manually applied fasteners to bind the NSIPs to the internal structural frame. The internal structural frame bears the structural load, leaving only transverse loads (e.g., wind loads) to be handled by the NSIP wall panels 102, window panels 108, and other non-load bearing elements such as a door, which allows for greater design flexibility and larger wall openings.

[0028] FIG. 2 illustrates component members of the internal structural frame 200, according to the present disclosure. The internal structural frame 200 is 3 dimensional frame formed of various vertical and horizontal members that are connected in a particular configuration that provides load bearing for the thermal envelope 100.

[0029] For instance, the internal structural frame 200 includes a first top horizontal member 202A that is coupled to a first vertical member 204A on a first end of the first top horizontal member 202A and a second vertical member 204B at the second end of the first top horizontal member 202A. The first vertical member 204A and the second vertical member 204B are connected to a bottom horizontal member 210A at opposite ends. The first top horizontal member 202A is additionally coupled to a first lateral member 206A that connects to a second top horizontal member 202B. The first top horizontal member 202A is additionally coupled to a second lateral member 206B that connects to a second top horizontal member 202B. The bottom horizontal member 210A is additionally coupled to a third lateral member 206C and a fourth lateral member 206D, which is connected to a second bottom horizontal member 210B. The internal structural frame 200 is a load-bearing structural frame that can be stacked or coupled to an additional internal structural frame depending on the size of the thermal envelope 100. The members of the internal structural frame 200 can be coupled to each other in any known manner, such as by welding or bolting the members together. Vertical and horizontal member components of the interior structural frame may be configured to form a substantially rectangular shape. However, at least some of the member components may also and/or alternatively be arranged diagonally or in other configurations to provide other frame shapes.

[0030] In an alternative embodiment, vertical members 204C and 204D may be different heights than vertical members 204A and 204B. A roof clip 212 attaches the roof non-structural laminated insulated panel at an angle as described and likely best understood with regard to FIG. 4.

[0031] The one or more bent clips 208 are coupled to the internal structural frame 200 and used to attach the non-structural insulated laminated wall panel to the internal structural frame 200. In one example, bent clips 208 can be attached to each of top horizontal members 202A-2B, bottom horizontal members 210A-B, lateral members 206A-D. In one example, a clip 208 has a first portion that is welded to the respective structural member, a second portion that is bent to define a gap between a third portion of the bent clip 208 and the respective structural member. The second portion of the bent clip 208 may be bent at various angles and create different sized gaps as determined by the specific design for the thermal envelope 100. Additional details of the bent clips are likely best understood with regard to FIGS. 3-5.

[0032] The internal structural frame may include mounting brackets 214 for securing the internal structural frame to a floor slab. In some configurations, mounting brackets 214 include a bolt, securing nut, and are welded to the respective vertical or lateral member of the internal structural frame 200. The internal structural frame 200 and the various vertical members and horizontal members may be made of iron, steel (e.g., stainless steel), aluminum, carbon fiber, or other suitable load bearing materials, or combination(s) thereof. The bent clips 208 may also be made of iron, steel (e.g., stainless steel), aluminum, carbon fiber, or other suitable materials for securing a load bearing structural frame to non-structural panels. Ideally, but not necessarily, the material(s) used to create the internal structural frame 200 and the bent clips 208 is or are resistant to rust. In some examples, a second internal structural frame may be stacked or positioned adjacent to the internal structural frame 200. Each internal structural frame may be used as a modular component for combining to create different thermal envelopes.

[0033] In an embodiment with stacked internal structural frames, the second internal structural frame may be positioned on top of the first internal structural frame to construct a modular thermal envelop that is taller than a modular thermal structure with a single internal structural frame. In an alternative embodiment with adjacent internal structural frames, the second internal structural frame may be positioned next to the first internal structural frame to construct a modular thermal envelop that is wider/longer than a modular thermal structure with a single internal structural frame. In either stacked or adjacent configurations, internal walls (and/or ceiling/floor) at the abutment of the frames may or may not be present. One of skill in the art would understand the many alternatives and structural variations of modular construction.

[0034] FIG. 3 illustrates a sectional view of a thermal envelope 300 with an internal structural frame, according to an embodiment of the present disclosure. While FIG. 3 illustrates a sectional portion of the thermal envelope 300, the thermal envelope 300 is formed (as shown in FIG. 1) by the connection of a first non-structural insulated laminated wall panel 302 and a roof non-structural insulated laminated panel 304. The internal structural frame 306 is positioned entirely within the thermal envelope 300. Corresponding connections between an additional non-structural insulated laminated wall panel 302 and an additional roof non-structural insulated laminated panel 304 form the thermal envelope 300 that is cutaway to show the sectional view. Accordingly, the internal structural frame 306 is entirely enclosed within the thermal envelope 300. The internal structural frame 306 may be coupled to a non-structural insulated laminated wall panel 302 (including an interior skin 312A and exterior skin 312B). Examples of the interior skin 312A or the exterior skin 312B includes high pressure laminate (HPL) by a bent clip 308. The bent clip 308 may have a first portion welded to the internal structural frame 306 while a second portion forms a gap between the bent clip 308 and the internal structural frame 306. The non-structural insulated laminated wall panel 302 is secured in the gap between the internal structural frame 306 and the bent clip 308. In one example, cutaway may be created in the NSIP 302 by way of precision cutting (e.g., hot wire cutting of the insulated core). As better shown in FIG. 4, the cutaway results in a tab-like structure on the interior skin 312A of the NSIP 302. This tab-like structure is the portion of the NSIP 302 that is secured in the gap between the internal structural frame 306 and the bent clip 308. The bent clip 308 may be formed from steel or another metal and welded the metal frame, to attach the non-structural insulated laminated wall panel to the structural frame quickly, strongly, and without the use of manually applied fasteners which compromise the integrity of the thermal envelope 300.

[0035] As illustrated in FIG. 3, the internal structural frame 306 includes a roof clip 314. The roof clip 314 may be similar to bent clip 308, but may be modified to have an angled portion. The angled portion of roof clip 314 may be formed such that the angled portion sets a slope of the roof non-structural insulated laminated panel 304. Additional description of the roof clip is described with regard to FIGS. 4A and 4B. The roof non-structural insulated laminated panel 304 may include multiple layers and in some cases, includes an exterior finished surface, interior finished surface, and additional layers. However, in other examples, the roof non-structural insulated laminated panel provides a substantially waterproof and airtight thermal envelope without requiring additional layers.

[0036] The thermal envelope 300 can also include a non-structural insulated panel strip (NSIP strip) positioned between a first non-structural insulated laminated wall panel 304 and an additional non-structural insulated laminated wall panel 304, a window panel 316, a door panel (not shown), or other components of the thermal envelope. A first NSIP strip 310A may be positioned in a cut-out or groove of the non-structural insulated laminated wall panel 304. A second NSIP strip 310A may be positioned in a cut-out or groove of the non-structural insulated laminated wall panel 304. The first NSIP strip 310 and the second NSIP strip 310B are precisely fitted using machined tolerances that allow the installation of the NSIP strips 310A and 310B to be substantially waterproof and airtight. The NSIP strips 310A and 310B seal any gap between adjacent non-structural insulated laminated wall panels, adjacent window panels, or other junctions of the thermal envelope. The precision fitting means that any mechanical fasteners are not necessary for the structure of the thermal envelope 300. Fabricating the thermal envelope without mechanical fasteners yields a bridgeless thermal envelope 300 that is free of mechanical thermal bridges that would penetrate into the thermal envelope 300.

[0037] For example, the non-structural insulated laminated wall panel is formed from precision fabrication of the rigid foam core. In some embodiments, the precise fabrication involves using a hot wire cutter to create precisely formed voids (obscured in FIG. 3) and slots in the SIP panels that allow the SIP panels to be attached to the metal frame, and to each other. The precise tolerances, which in some embodiments may be between 1/32- 1/64, achieved through computer-controlled, factory-based fabrication and assembly are necessary for realizing the full benefits disclosed herein. For example, precisely-sized parallel voids cut into the top surface of the rigid foam core of each NSIP 302 creates a thin vertical structure that fits precisely under the bent clip 308. Slots formed into the vertical edges of the NSIP walls 302 allow the NSIP strips 310A and 310B to be inserted into the vertical edges of adjacent NSIP walls 302, and/or NSIP walls 302 and adjacent window members 316. The precision fit of the voids in the rigid foam to the bent clips and NSIP and window NSIP strips 310 (e.g., a NSIP strip modified to fit to a window frame) allows for a strong, airtight, and watertight connection throughout the thermal envelope 100. In some cases, a frame of the window may include a bent clip for coupling the NSIP walls 302. In some examples, an adhesive may be used at the connections of the NSIP strips 310 to the non-structural insulated laminated wall panel 304 to eliminate the need for fasteners at the adjacent NSIP connection, resulting thermal envelope 100, which can be continuous and monolithic. In some embodiments, the bent clip 308 may be used in a similar way to secure decorative features to an interior of the internal structural frame to obscure the internal structural frame from visual observation from inside the thermal envelope.

[0038] The fabrication method of the non-structural insulated laminated wall panels 302 allows for the use of any sheet material that possesses the necessary strength and weather-resistant properties to serve as the exterior and interior skins. The fabrication method thus allows a wide range of products and architectural aesthetics including, but not limited to, high pressure laminates, cement fiber panels, porcelain sheets, fiberglass composites, metal, wood composites, and ceramics. The use of precisely fabricated voids and fit of the NSIPs at the adjacent NSIP connection creates an attractive, clean-lined architectural detail known as a reveal, which is usually prohibitively complicated to implement using site-built construction methods, but is available with this method of prefabricated construction. The result is a finished wall stem that achieves high-end construction details, paired with high-quality, maintenance free, commercial grade materials, at a fraction of the cost of conventional construction by using a simplified 3-part assembly that produces superior results.

[0039] FIG. 4A illustrates an expanded sectional view of a roof and wall connection that forms one edge of the thermal envelope 100.

[0040] For example, a bent clip 308 is attached to the internal structural frame 306. The bent clip 308 may have a first portion welded to the exterior side 309 of the internal structural frame 306 while another portion forms a gap between the bent clip 308 and the internal structural frame 306. As shown, in one example, the first portion of the bent clip 308 may be is parallel to and welded to the exterior side 309 of the structural frame 306. The second portion of the bent clip 309 may be below the first portion and may extend perpendicular or substantially perpendicular to the exterior side 309 of the structural frame 306 and may then be bent downward so as to again be parallel or substantially to the exterior side 309, thus forming the aforementioned gap. Other configurations of the bent clip 308 are possible. For example, the first portion of the bent clip 308 may be below the perpendicular section of the second portion. In one example, a slot 307 is cut into the NSIP wall 302 such that the interior panel (e.g., the interior skin 312A) of the NSIP wall 302 fits into the gap between the internal structural frame 306 and the bent clip 308. In some embodiments, materials other than HPL may be used for the interior skin 312A or exterior skin 312B of the NSIP. The roof clip 314 is a similar bent clip that may be angled at any suitable angle for an architectural roofing plan. The roof clip 314 secures the roof non-structural insulated laminated panel 304 to the top of each non-structural insulated laminated wall panel 302. In some embodiments, the roof non-structural insulated laminated panel 304 have precision gaps cut into the foam core to fit the roof clip 314. The roof clip 314 can also include an angled bracket that provides an angular offset from the internal structural frame 306 to provide a roof angle. The roof may include multiple roof non-structural insulated laminated panels 304.

[0041] FIG. 4B illustrates a completed sectional view roof and wall connection, according to the present disclosure. The internal structural frame 306 is illustrated inside the edge of the thermal envelope formed by roof non-structural insulated laminated panel 304 to the non-structural insulated laminated wall panel 302. The bent clip 308 secures the non-structural insulated laminated wall panel 302 to the internal structural frame 306.

[0042] FIG. 5 illustrates a sectional view of a floor and wall connection of the thermal envelope, according to the present disclosure. The sectional view includes a non-structural insulated laminated wall panel 302, a mounting bracket 502, a grounding bolt 504, a securing nut 506, a floor 508, and a ground environment 510.

[0043] For example, the non-structural insulated laminated wall panel 302 is secured to the floor 508 by a mounting bracket 502. The non-structural insulated laminated wall panel 302 is secured into position by mechanical cooperation of the mounting bracket 502, the grounding bolt that passes through an opening in the mounting bracket and penetrates into the floor 508. In one example, the floor 508 may be concrete and is poured over the grounding bolt 504. The grounding bolt is fixed into position by securing nut 506 threaded onto the grounding bolt until the bottom face of the mounting bracket is flush against the floor 508. In some embodiments, various electrical, plumbing and other conduits may be formed or otherwise provided in the floor 508 for running wires and plumbing within the structure and awithout compromising the thermal envelope 100.

[0044] FIGS. 6A and 6B illustrate a junction between non-structural insulated laminated wall panels including a NSIP strip. The junction includes a first non-structural insulated laminated wall panel, a NSIP strip, and a second non-structural insulated laminated wall panel. As illustrated by FIG. 4A, more than one NSIP strip can be utilized at each junction (e.g., the exterior skin and interior skin may each have an NSIP strip).

[0045] FIG. 6A illustrates an expanded sectional view of a junction between non-structural insulated laminated wall panels, according to the present disclosure. The first non-structural insulated laminated wall panel 602 has an exterior groove 604 and an interior groove 606 that are precisely cut into the rigid foam insulation to accommodate an exterior NSIP strip 608 and an interior NSIP strip 610. The second non-structural insulated laminated wall panel 612 also has an exterior groove 604 and an interior groove 606. The exterior NSIP strip 608 and the interior NSIP strip 610 are precisely formed to fit into the exterior groove 604 and the interior groove 606 respectively. Each of the NSIP strip 610, the top of first non-structural insulated laminated wall panel 602, or the bottom of second non-structural insulated laminated wall panel 612 can have adhesive 614 applied to further improve the quality of the junction. In some embodiments, such an adhesive may be similarly applied at the junction of an NSIP 302 and a bent clip 306. An example of preferred adhesives are bonding mixtures that are flexible and resilient against movement, temperature and moisture. Some appropriate adhesives may include, glue, epoxy, and/or rubber cement. Instead of or in addition to an adhesive, caulking can be applied to seal the junctions.

[0046] FIG. 6B illustrates a completed sectional view of a junction between non-structural insulated laminated wall panels, according to the present disclosure. As compared to FIG. 6A, FIG. 6B depicts the precision manufacturing and tolerances of the interior groove and exterior groove so that the NSIP strips fit tightly with minimal additional gap to ensure the integrity of the thermal envelope.

[0047] FIG. 7 illustrates a process 700 of manufacturing a thermal envelope with an internal structural frame, according to the present disclosure.

[0048] At block 702, the process 700 involves forming an internal structural frame. The internal structural frame may be formed from steel or another load bearing material sufficient to support the load of the thermal envelope. In one example, the internal structural frame is formed by fabricating vertical, horizontal, and lateral members and then securing the members together in the desired shape of the thermal envelope. Some of the members may be diagonal to create more variety in shapes for the thermal envelope.

[0049] At block 704, the process 700 involves welding a bent clip onto the exterior and surfaces of each top and bottom horizontal members and each respective lateral member of the internal structural frame. For instance, each bent clip may be welded to the relevant member of the internal structural frame as described with regards to FIGS. 1-6. In some embodiments, the bent clips are steel-welded to a steel internal structural frame, however, other methods of precision attachment both known and future do not depart from the teachings of the present disclosure.

[0050] At block 706, the process 700 involves securing NSIPs to each exterior side of the internal structural frame using the bent clips, so as to enclose the frame. For instance, precision cuts to form voids in an NSIP can be made to accommodate the bent clip, as previously described.

[0051] At block 708, the process 700 involves applying NSIP strips at the vertical junctions of NSIP panels. As described with regards to FIGS. 1-6, NSIP strips are applied in exterior or interior groves cut into the rigid foam of the NSIP panel to ensure integrity of the thermal envelope.

[0052] Having described several example configurations, various modifications, alternative constructions, and equivalents may be used without departing from the spirit of the disclosure. For example, the above elements may be components of a larger system, wherein other rules may take precedence over or otherwise modify the application of the invention. Also, a number of steps may be undertaken before, during, or after the above elements are considered.

[0053] Further details of various embodiments of the invention are shown and described in the attached drawings. It will be understood that the items and components shown in the drawings are not drawn to scale and are not meant to convey any particular size, shape or other configuration limitations. To the contrary, the modular components of the inventive pre-fabricated unit are fully customizable by size, shape, dimensions, orientation, and configuration, allowing for the construction of customized dwellings and other structures. In addition, the materials used for the described framing, NSIPs and other components of the invention are described in the context of various preferred or possible embodiments and by way of example only. Other types of materials may be substituted in some cases, provided such materials provide the same, comparable or desired properties and benefits, such as the above-described strength, insulation, weight, weather-resistant and aesthetic properties.