Method of making members with a thermal break

Abstract

Method of forming members from thermally conductive components which have a gap therebetween. The gap is bridged and the conductive components integrated into a composite member by a reinforced polymer. This provides a thermal break which inhibits the flow of heat between the conductive components of the member. This construction also blocks the transfer of sound and other vibrations between the conductive components of the member. The construction also mitigates the formation of condensation on an artifact fixed to one of the components. After the gap is bridged with the reinforced polymer, the member may be punched with holes and roll formed.

1 . A method of manufacturing a member capable of blocking the transfer of heat and vibrations from a first to a second side of the member, said member having a web comprising the steps of: 
 arranging an assembly of first and second conductive components of said web in side-by-side relation with a gap between complementary surfaces of said first and second conductive components; and    bonding an insulation material having an upper and lower side capable of inhibiting the transfer of heat between said components in gap spanning relationship to the first and second conductive components to form a thermal break between said first and second components and to form a unitary assembly of said first and second conductive components and the insulation material; and    applying a fire retardant to at least one side of the insulation material.    
   
   
       2 . A method as defined in  claim 1  in which the insulation material comprises a reinforced polymer.  
   
   
       3 . A method as defined in  claim 2  in which the polymer is a polypropylene.  
   
   
       4 . A method as defined in  claim 3  wherein the polypropylene is one which will so change character upon being heated as to increase the thermal resistance offered by the third component.  
   
   
       5 . A method as defined in  claim 1  which said insulation material is adhesively bonded to said first and second conductive components.  
   
   
       6 . A method as defined in  claim 1  in which the configuration of at least one of said first and second conductive components is altered after the insulation material is bonded to said first and second conductive components of said web.  
   
   
       7 . A method as defined in  claim 6  in which the configurations of the first and second conductive components are so altered that the member has integral flanges at opposite sides of the web.  
   
   
       8 . A method as defined in  claim 1  in which at least one of the first and second conductive components has through apertures.  
   
   
       9 . A method as defined in  claim 1  in which the first and second conductive components are preheated, in which first an adhesive and then the insulation material are applied to said components, and in which the resulting assemblage of first and second conductive components and insulating material is then cooled to set a polymeric component of the insulating material.  
   
   
       10 . A method as defined in  claim 9  in which said adhesive and insulation material are applied to first and second, opposite sides of the first and second conductive components, respectively.  
   
   
       11 . A method as defined in  claim 1  in which an aperture is formed through the assemblage of first and second conductive components and insulation material and in which a flanged bushing is thereafter installed in the aperture to protect the structural integrity of the member and to prevent damage to articles in or passed through said aperture.  
   
   
       12 . A method as defined in  claim 8  in which said apertures are on opposite marginal edges of the first and second conductive components of said web to accommodate the flow of the said insulation material thereby promoting a bond between said insulation material on opposite sides of said first and second conductive components, and anchoring said insulation material to the first and second components of the web.  
   
   
       13 . A method as defined in  claim 12  in which there are at least two rows of apertures in the marginal edge of at least one of the first and second conductive components, the apertures in said rows being so staggered as to lengthen thermally conductive spanwise paths through each component in which the apertures are formed, thereby impeding the transfer of heat between inner and outer faces of the member.  
   
   
       14 . A method as defined in  claim 1  in which said insulation material is bonded to only one side of said first and second conductive components.  
   
   
       15 . A method as defined in  claim 1  wherein the assemblage of said first and second conductive components and said insulation material is cut to a predetermined length.  
   
   
       16 . The method of  claim 12  wherein said first and second conductive components are pre-heated prior to bonding said insulation material thereto.  
   
   
       17 . The method of  claim 1  which includes guiding said first and second conductive components so that said gap between said complementary surfaces of said first and second conductive components is maintained prior to bonding said insulation material to said first and second conductive components.  
   
   
       18 . The method of  claim 17  wherein cam rolls abut the first and second conductive components so that the said gap between said complementary surfaces of said first and second conductive components is maintained prior to bonding said insulation material to said first and second conductive components.