Insulated Box Beam Framing Member

Abstract

A fabricated framing member constructed primarily of wood products that is used as a stud, joist, or rafter to construct walls, floors, or ceilings. Lumber is normally used for these purposes, however, the thermal performance, dimensional accuracy, and dimensional stability of lumber is not as good as desired. The invention improves these and other qualities by strategically minimizing the amount of wood products used and by the addition of insulation. The shape of the structural portion of the member is similar to the shape of an elongated box and insulation fills the inside of that box.

Claims

1. A fabricated framing member for use in building a structure and that is comprised of: a) a first elongate flange component extending from one end of the member to the other end, having an inward face, an outward face, a pair of side faces which extend between the inward and outward faces, two end faces, and being formed from a structural material; b) a second elongate flange component, oriented substantially parallel to the first elongate flange component, spaced some distance from the first elongate flange component, extending from one end of the member to the other end, having an inward face, an outward face, a pair of side faces which extend between the inward and outward faces, two end faces, and being formed from a structural material; c) a pair of elongate web components, each affixed to and extending from a side face of the first elongate flange component and extending to the cooresponding side face of the second elongate flange component, and affixed thereto, oriented substantially parallel to the elongate flange components, having an inward face, an outward face, two edge faces, two end faces, and being formed from a structural material other than oriented strand board (OSB) and from a material which is substantially solid and which provides substantial compressive, tensile, and shear strength; wherein the first and second elongate flange components and the pair of elongate web components assume the shape of a rectangular tube the length of the member where: a) the inward faces of the flange components and the exposed portion of the inward faces of the web components define an elongated interior rectangular surface of a rectangular tube, and b) the outward faces of the flange components and the outward and edge faces of the web components define the outer surface of a rectangular tube wherein the elongated interior rectangular surface extends from one end of the member to the other and defines an oblong box shaped cavity within the member, wherein the oblong box shaped cavity within the member is substantially filled with insulative material of any kind, and wherein the insulative material is either formed against, or assembled into and optionally adhered to, the elongated interior rectangular surface defining the oblong box shaped cavity within the rectangular tube shaped member.

2. The insulated member of claim 1; wherein end connection blocks made of solid structural material are affixed between the flange and web components at each end of the member displacing a portion of the interior insulation of the member; wherein the end connection blocks have an inward face, an outward face, a top face, a bottom face, and two side faces; wherein the inward face of each end connection block borders on, and may be affixed to, the interior insulation; wherein the outward face of each end connection block is flush with the end of the member; wherein the top face of each end connection block is affixed to the inward face of the first elongate flange component; wherein the bottom face of each end connection block is affixed to the inward face of the second elongate flange component; and wherein the side faces of each end connection block are affixed to the inward faces of the elongate web components.

3. The insulated member of claim 1 wherein one or more apertures are formed into the web components such that the aperture space within the thickness of the web component may or may not be filled with insulation.

4. The insulated member of claim 1 wherein reinforcing material is affixed to the elongate flange and elongate web components where they contact each other and/or against the inside face of each flange component or in a portion of the spaces described.

5. The insulated member of claim 1; wherein plate blocks are affixed between the flange and web components at each end of the member and at either 12, 16, or 24 inch centers along the length of the member, and displacing portions of the interior insulation of the member; wherein the plate blocks have two longitudinally oriented faces, a top face, a bottom face, and two side faces; wherein the two longitudinally oriented faces of the plate blocks border on the interior insulation of the member or may be flush with the end of the member; wherein the top face of each plate block is affixed to the inward face of the first elongate flange component; wherein the bottom face of each plate block is affixed to the inward face of the second elongate flange component; wherein the side faces of each plate block are affixed to the inward faces of the elongate web components, and wherein the plate blocks are made of a solid structural material.

6. The insulated member of claim 1; wherein end connection blocks are affixed between the flange and web components at each end of the member displacing a portion of the interior insulation of the member; wherein the end connection blocks have an inward face, an outward face, a top face, a bottom face, and two side faces; wherein the inward face of each end connection block borders on, and may be affixed to, the interior insulation; wherein the outward face of each end connection block is flush with the ends of the member; wherein the top face of each end connection block is affixed to the inward face of the first elongate flange component; wherein the bottom face of each end connection block is affixed to the inward face of the second elongate flange component; wherein the side faces of each end connection block are affixed to the inward faces of the elongate web components; wherein the end connection blocks are made of a solid structural material, and wherein one or more apertures are formed into the web components such that the aperture space within the thickness of the web component may or may not be filled with insulation.

7. The insulated member of claim 1; wherein end connection blocks are affixed between the flange and web components at each end of the member displacing a portion of the interior insulation of the member; wherein the end connection blocks have an inward face, an outward face, a top face, a bottom face, and two side faces; wherein the inward face of each end connection block borders on, and may be affixed to, the interior insulation; wherein the outward face of each end connection block is flush with the end of the member; wherein the top face of each end connection block is affixed to the inward face of the first elongate flange component; wherein the bottom face of each end connection block is affixed to the inward face of the second elongate flange component; wherein the side faces of each end connection block are affixed to the inward faces of the elongate web components; wherein the end connection blocks are made of a solid structural material, and wherein reinforcing material is affixed to the elongate flange and elongate web components where they contact each other and optionally affixed to the end connection blocks and elongate web components where they contact each other and optionally against the inside face of each flange component or in a portion of the spaces described.

8. The insulated member of claim 1; wherein one or more apertures are formed into the web components such that the aperture space within the thickness of the web component may or may not be filled with insulation; and wherein reinforcing material is affixed to the elongate flange and elongate web components where they contact each other and/or against the inside face of each flange component or in a portion of the spaces described.

9. The insulated member of claim 1; wherein end connection blocks are affixed between the flange and web components at each end of the member displacing a portion of the interior insulation of the member; wherein the end connection blocks have an inward face, an outward face, a top face, a bottom face, and two side faces; wherein the inward face of each end connection block borders on, and may be affixed to, the interior insulation; wherein the outward face of each end connection block is flush with the end of the member; wherein the top face of each end connection block is affixed to the inward face of the first elongate flange component; wherein the bottom face of each end connection block is affixed to the inward face of the second elongate flange component; wherein the side faces of each end connection block are affixed to the inward faces of the elongate web components; wherein one or more apertures are formed into the web components such that the aperture space within the thickness of the web component may or may not be filled with insulation, and wherein reinforcing material is affixed to the elongate flange and elongate web components where they contact each other, and optionally between the end connection blocks and the elongate web components where they contact each other, and optionally against the inside face of each flange component or in a portion of the spaces described.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0039] FIG. 1A shows a simple wall frame assembly (101) as per prior art with studs (100), top plate (102), and sill plate (103).

[0040] FIG. 1B shows the top view of an insulated wall assembly (104) with insulation (107) installed into the wall cavities between the studs (100), sheathing (105), and gypsum wall board (106).

[0041] FIG. 1C shows a side view of another typical wall frame (101) of prior art and names various elements used in the wall frame.

[0042] FIG. 2 shows the location of the greatest stress in a framing member when it is loaded in the strong axis.

[0043] FIG. 3 shows the location of the greatest stress in a framing member when it is loaded in the weak axis.

[0044] FIG. 4 shows four views of the present invention with optional end connection blocks (403) installed. The flanges (402) are fixed in place relative to each other by two web plates (401) and the end connection blocks (403). The geometry forms a long box made of wood products. This box is filled with insulation (404).

[0045] FIG. 5 shows four views of the present invention with optional pre-drilled holes (505) for easy installation of utilities at the construction site and for installation of foam-in-place insulation (404) in the factory.

[0046] FIG. 6 shows the predicted location of optional reinforcement material (607).

[0047] FIG. 7 shows the option of plate blocks (701) to increase compressive strength when used as a plate.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0048] The construction of the preferred embodiment is as follows. It is not the only embodiment possible and variations and optional features will also be discussed.

[0049] The IBBFM is made of two elongate flanges (402) spaced at some distance from each other and fixed into position by two elongate webs (401) which are adhered to the side faces of the elongate flanges thereby creating a rectangular tube shaped member. The inside of the tube is filled with insulation (404).

[0050] The IBBFM is purposely not dimensioned since variations in the dimensions of all the components could be used to adjust the properties of this invention to optimize it for specific purposes. For example: one application may require more strength while another requires greater insulation. Even though a preferred embodiment results in overall dimensions equivalent to standard dimensional lumber (commonly 1.5″×5.5″), other dimensions could be useful and are also claimed in the present invention. For example, sills (110) and headers (111) could be manufactured in a factory at a specified length, thickness, and height.

[0051] FIG. 4 shows a preferred embodiment of the present invention which has two webs (401) located on the exterior of the member rather than one web in the center (as in the I-Beam studs). This geometry has the advantages of protecting the insulation (404) contained within the member, and of adding stiffness when the member is in compression (due to this shape's greater radius of gyration).

[0052] The IBBFM design (FIG. 4) is an assembly of multiple pieces rather than being constructed of a single piece of wood. This has the advantage of creating a more dimensionally correct and stable product (helping to prevent twist, bow, and crook).

[0053] The IBBFM (FIG. 4) could be assembled with glue or fasteners or a combination of the two. Although any of its pieces could be made of solid wood or many engineered wood composites, in a preferred embodiment, the flanges (402), end blocks (403) and plate blocks (701) would be made from solid natural wood while the webs (401) would be made of plywood.

[0054] In a preferred embodiment, the insulation (404) would be a polyurethane foam formed within the cavity of the IBBFM. Not only does polyurethane foam perform best thermally, but it also has the additional advantage over other insulation types of contributing to the structural strength due to its inherent strength and its ability to bond to the flanges (402) and side plates (401). The IBBFM (FIG. 4) could also use other types of insulation to achieve a lower cost. Pre-formed foam (such as extruded or expanded polystyrene for examples) insulation of any type could be cut and glued into the cavity during assembly rather than forming the foam within the cavity. Insulation product technology is constantly improving and new insulations which have yet to be developed or brought to market may become the best choice for the present invention. The use of the present invention with any type of insulation is claimed.

[0055] The embodiment shown in FIG. 4 includes optional end connection blocks (403) which make attachment to plates (102 & 103) easier when used as a wall stud but could be omitted when used for other purposes. Similar to the end connection blocks are the plate blocks shown in FIG. 7. These plate blocks can be installed when the member is used as a sill plate (103) or top plate (102) to transfer the compressive load through the plate to the surface above or below. This type of blocking is not novel. It is a method well known to those skilled in the art of construction. This blocking may be made of wood or an engineered wood product.

[0056] FIG. 5 shows how holes (505 & 506) could be pre-drilled in various places of the webs (401) to make the installation of utilities faster and easier at the construction site and/or to aid in installing the foam insulation in the factory. The use of holes for these purposes is not novel. It is a feature well known to those skilled in the art of construction. In a preferred embodiment, the holes are drilled through the structural material only and not through the insulation. The insulation can remain at the inward surface of the side plate as shown in 505 or be filled flush with the outward surface of the side plate (401) as shown in FIG. 5. (506).

[0057] Although the IBBFM would typically be made of wood or engineered wood products, other non-metallic materials or combinations of materials may also be used except that oriented strand board (OSB) and/or particle board may not be used for the side flanges (401). The type of insulation, glue, fasteners, and optional reinforcement are also not specified since the present invention could utilize many different types of materials for these things. Some types of glue that would commonly be used are epoxy, urea formaldehyde, melamine, or phenolic.

[0058] When greater strength is needed in a portion of the member, reinforcement material could be installed in that portion between the flanges (402), end connection blocks (403), and the side plates (401). The reinforcement material could be carbon fiber, fiberglass, or other high strength material. The predicted beneficial location of the reinforcing fibers is shown in FIG. 6. The reinforcing material would ideally be attached to both the flanges (402) and the side plates (401) possibly imbedding it in the adhesive joining the two. The precise location of the reinforcing fibers could be determined by computer modelling and/or break testing and could be installed only where needed.

[0059] The insulated box beam framing member invention proposed herein has the advantage of being most similar to the common framing members that construction crews are already familiar with. This means that additional framing time or training of construction workers is minimized.

[0060] The overall strength of various embodiments of this invention will be less than a solid wood member of the same overall size, however, buildings are commonly designed with more strength than necessary in certain elements to allow the use of standard dimensioned building materials. This means that in many situations, this invention could be a direct replacement for standard dimensional lumber.

[0061] The shape of the member could be optimized further than the embodiments shown. One way to do this is with a computerized finite element analysis program such as STAAD or RISA. Also, strength testing could create a database that architects and engineers could use to incorporate this invention into their designs. This invention could also be made in custom lengths or widths for convenient use as sills(103, 110), headers(111), cripples(112), or other framing components. The idea claimed includes variations in actual dimensions, materials, and features described in this specification in order to achieve performance needed for particular applications. For example: Some applications may require more strength while others may need more insulation value. Optimization of the shape and dimensions of the member could further improve performance and is also claimed.

[0062] This invention could be used in walls (as in FIG. 1A-1C), floors, or ceilings where improved insulation characteristics are desired. By decreasing the thermal conductivity of a wall assembly, for example, the need for a continuous layer of insulation outside of the sheathing is reduced or eliminated. A continuous layer of foam insulation outside of the sheathing has become a common way to overcome the poor thermal properties of common framing members but using that method complicates moisture control design and exterior flashing methods.

[0063] The manufacture of this invention could be done in a variety of ways from a simple assembly jig to an automated production line process. The best choice will depend on the production volume needed.