Reinforced insulated framing member

Abstract

 The invention relates to a framing member (10) comprising two structural members (11) and an insulating material (12) laying against inside facing surface areas of the structural members. The framing member further comprises one or more reinforcing elements (13) that are each in contact with the insulating material and the adjacent structural members, wherein the material of the reinforcing elements is sawable.
The invention further relates to a method of producing a framing member according to the invention, wherein the reinforcing elements comprise fibre elements, preferably fibre mats.

Description

[0001] The present invention relates to a framing member comprising two structural members and an insulating material lying against inside facing surface areas of the structural members.

[0002] As an example framing members, such as studs or rails, with an integrated thermal break are known in the art and allow achieving the prescribed values for the total thermal resistance R_c even in thin constructions.

[0003] In the field of building and framing construction materials said framing members with an integrated thermal break can be used in various construction applications, such as in walls, roofs, door frames, window frames, floors and other load bearing and non-load bearing elements where a framing member is used.

[0004] In many construction applications high structural loads are carried by said framing members. As the known framing members are manufactured from layers of non-homogenous materials, they may pull apart or de-laminate over time due to these loads and forces acting thereon.

[0005] The present invention provides a solution to the problem by providing a framing member according to the preamble, wherein the framing member further comprises one or more reinforcing elements that are each in contact with the insulating material and the adjacent structural members.

[0006] By connecting the alternating layers of structural members and the insulating material therein between by the reinforcing members the strength of the framing member is significantly enhanced.

[0007] It is noted that as an example US2012/0011793 also addresses the above problem of insulated framing members by enhancing the adhesion characteristics thereof. Thereto complex forms, such as dovetails, are cut into the inside facing surface areas of the structural members, which complex forms are filled with insulating material. These additional production steps require much more effort than arranging reinforcing elements according to the present invention.

[0008] In the framing member according to the preamble of claim 1 the reinforcing elements comprise fibre elements, preferably fibre mats. Fibres are a sawable material that allows for optimal processing of the framing members as it can be cut quickly into any desired dimensions using conventional wood processing tools.

[0009] A framing member according to the preamble of claim 1 is known from WO 99/61718. In the known framing member a fibre strip is installed in a groove in the wooden upper and lower constructional element. WO 99/61718 is silent about suitable production methods of the known framing member, but any production method will involve making a groove in each constructional element and placing the fibre strips in the grooves.

[0010] The invention has for its purpose to provide a framing member that can be easily produced in a variety of dimensions depending on the application.

[0011] The framing member according to the invention is characterized in that each of the two structural members is composed of parts adhered together with the interposition of the fibre elements. The framing member produced by the method according to the invention is easily recognizable by an adhesion surface extending through the entire structural elements.

[0012] The invention further relates to a method of producing such a framing member, comprising the steps of:

a) Composing at least each structural member of parts

b) Arranging the parts of each structural member opposite each other

c) Placing fibre elements, preferably arranged in mats, against the opposing surfaces of the parts; and

d) Adhering the parts together.

[0013] According to a first preferred embodiment the method according to the invention comprises the step of:

a) Sawing a framing member comprising two structural members and an insulating lying against the inside facing surface areas of the structural members into parts along a plane extending through the structural members and the insulating material;

b) Placing fibre elements, preferably arranged in mats, against the sawing surfaces of the parts; and

c) Adhering the parts together.

[0014] According to a second preferred embodiment the method according to the invention further comprises step e) of: choosing a foam as the insulating material and applying the foam against the inside facing surface areas of the adhered structural members, thereby making the foam surround the fibre elements.

[0015] Preferably the material of the structural members is: wood, including finger jointed and/or laminated wood, structural composite lumber, such as laminated strand lumber (LSL), laminated veneer lumber (LVL) and micro laminated lumber, oriented strand board (OSB), plywood, pressed wood, laminated layered board, synthetic wood or hardboard.

[0016] Preferably the insulating material is mineral wool, non-mineral wool, foam, cellulose material or combinations thereof.

[0017] The invention will now be elucidated in more detail herein below with reference to the drawings, in which:

Figure 1A schematically shows a first embodiment of a framing member according to the invention in longitudinal cross section;

Figures 1B and 1C schematically illustrate different steps of a first method of producing the framing member of figure 1A;

Figure 1D schematically shows the framing member of figure 1A in transverse cross section;

Figure 2A illustrates a different step of a second method of producing a framing member according to the invention; and

Figure 2B schematically shows a second embodiment of a framing member according to the invention in transverse cross section.

[0018] Figures 1A and 1D show a first preferred embodiment 30 of a framing member according to the present invention. Figure 1A shows framing member 30 in longitudinal cross section, whereas figure 1D shows framing member 30 in transverse cross-section. The cross sectional lines are C-C'.

[0019] Framing member 30 has a typical elongated shape like a beam. Framing member 30 is layered of non-homogeneous material. Framing member 30 comprises two substantially parallel structural members 31 and an insulating material 32 lying there in between. The structural members 31 provide the majority of the mechanical properties of the framing element. The insulating material 32 provides the insulation property to the framing element, serving as a thermal break between the two elongated structural elements.

[0020] Framing member 30 comprises reinforcing elements 33 that are in contact with both the structural members 31 and the insulating material 32 lying there in between.

[0021] Reinforcing elements 33 comprise fibre elements. Preferably the fibre elements are arranged in mats. Suitable fibre elements are of sawable materials and include synthetic fibres, such as aramid fibres. In the context of this invention sawable materials are materials that can be easily processed using conventional (wood) processing tools.

[0022] The framing member according to the invention can be produced based on the insight that at least each structural member is to be composed of parts that need to be arranged opposite to each other, whereby fibre elements, preferably arranged in mats, are placed against the opposing surfaces of the parts and the parts are adhered together.

[0023] According to a first method, framing member 30 can be produced starting from a standard framing member 20 comprising alternating layers of structural elements and an insulating material.

[0024] In a first step, illustrated in figure 1B, the standard framing member 20 is sawn into two parts along a plane extending through the structural members and the insulating material. This plane preferably lies in the centre and comprises line C-C' in figure 1B.

[0025] In a next step, illustrated in figure 1C, fibre elements 33, preferably arranged in mats, are placed against the sawing surfaces of the two parts 20A and 20B.

[0026] Then the parts 20A and 20B are adhered together under pressure (in the direction of the arrows in figure 1C) using suitable adhesion substances known in the art.

[0027] Alternatively, framing member 40 can be produced by a second method according to the invention, illustrated in figure 2A.

[0028] In a first step each structural member is composed of parts 41A, 41 B that are arranged opposite to each other and the fibre elements 33, preferably arranged in mats, are placed between the opposing surfaces of the parts and the parts are adhered together. A foam 42 is chosen as the insulating material and applied against the inside facing surface areas of the adhered structural members, thereby making the foam surround the fibre elements and forming the core of the framing member.

[0029] Materials for structural members used in the invention can be selected from a variety of sources including materials used commonly in the art. Lumber may be obtained from timber. Timber cut and prepared into boards planks or other ready for market pieces. Specific to this application the pieces marketed for use framing and building during construction. As used in this application, both wood; engineered wood (combined particles, strands, or veneers with a glue, polymer, composite or similar bond); and other materials used for the purpose of building and framing in the way that cut timber is traditionally used for framing and building.

[0030] Insulation is a low energy transmission material used in construction or manufacturing to slow the transfer of heat, sound, or other energy through materials. Typically strong structural materials have a high capacity to transfer heat and other energies through walls, roofs, and floors and insulation is added to structure so the combined transfer of energy is reduced and the structure becomes more energy efficient, less noisy and otherwise more comfortable. Rigid closed cell polyurethane, open cell polyurethane, ceramics, and urethane are examples of insulation that could be used for insulated lumber applications. Mineral wool, non-mineral wool, and blown cellulose are examples of insulation that do not have structural value for use in insulated lumber.

[0031] The foregoing examples are intended to be illustrative and not exclusive.

[0032] The invention is of course not limited to the described and shown preferred embodiments, but also explicitly includes all combinations thereof. The invention relates generally to any embodiment falling within the scope of protection as defined in the claims and as seen in the light of the foregoing description and accompanying drawings.

Claims

1. Framing member comprising two structural members and an insulating material laying against inside facing surface areas of the structural members, the framing member further comprises one or more reinforcing elements that comprise fibre elements, preferably fibre mats, that are each in contact with the insulating material and the adjacent structural members, characterized in that each of the two structural members is composed of parts adhered together with the interposition of the fibre elements.

2. Framing member according to one or more of the preceding claims, wherein the material of the structural members is: wood, structural composite lumber, oriented strand board (OSB), plywood, pressed wood, laminated layered board, synthetic wood or hardboard.

3. Framing member according to one or more of the preceding claims, wherein the insulating material is mineral wool, non-mineral wool, foam, cellulose material or combinations thereof.

4. Method of producing a framing member comprising two structural members and an insulating material laying against inside facing surface areas of the structural members, the framing member further comprises one or more reinforcing elements that comprise fibre elements, preferably fibre mats, that are each in contact with the insulating material and the adjacent structural members, comprising the steps of:

a) Composing at least each structural member of parts

b) Arranging the parts of each structural member opposite each other

c) Placing fibre elements, preferably arranged in mats, against the opposing surfaces of the parts; and

d) Adhering the parts together.

5. Method according to claim 4, comprising the steps of:

a) sawing a framing member comprising two structural members and an insulating material laying against the inside facing surface areas of the structural members into parts along a plane extending through the structural members and the insulating material;

b) Placing fibre elements, preferably arranged in mats, against the sawing surfaces of the parts; and

c) Adhering the parts together.

6. Method according to claim 4, further comprising step e) of: choosing a foam as the insulating material and applying the foam against the inside facing surface areas of the adhered structural members, thereby making the foam surround the fibre elements.

Drawing