Thermal stud or plate for building wall

Abstract

A metal thermal stud/plate has a center web with geometrically-shaped apertures spaced longitudinally along its centerline. The apertures define alternatingly-positioned narrow necks of material therebetween near ends of the center web. The narrow necks minimize thermal conductivity between the spaced flanges, but adjacent ones of the narrow necks are longitudinally misaligned due to their alternating positions to thus prevent forming a weak longitudinally-extending fold line in the stud/plate, thus maintaining its strength. In one form, the narrow necks are at most about 0.100 inches wide without substantially degrading the strength of the studs/plates, or can be a ratio of neck width to center web of as low as 0.09:4 down to 0.03:4. A building wall frame includes a plurality of the metal studs/plates and foam insulated panels with edges engaging the center webs of adjacent studs/plates to thus stabilize the metal studs/plates.

1 . A thermal structural component comprising:
 a metal structural beam component having a center web and spaced flanges forming one of an I-beam shape, channel shape, or a C-beam shape, the center web including a longitudinal centerline and including geometrically-shaped apertures spaced longitudinally along the centerline, the apertures each extending onto both sides of the centerline and including first and second portions that define different shapes relative to the centerline and that are in alternating positions on opposite sides of the centerline in each successive aperture, the first and second portions of adjacent ones of the apertures defining at least one narrow neck of material therebetween that is located near a flange-adjacent end of the center web, the narrow neck minimizing thermal conductivity between the spaced flanges, but adjacent ones of the narrow necks being longitudinally misaligned due to their alternating positions to thus prevent forming a weak longitudinally-extending fold line in the beam component such that a strength of the beam component is substantially maintained.   
     
     
         2 . The thermal structural component as defined in  claim 1 , wherein the necks have a first width, and the center web has a second width, a ratio of the first width to the second width being at most about 0.25:4. 
     
     
         3 . The thermal structural component as defined in  claim 2 , wherein the ratio is at most about 0.1:4. 
     
     
         4 . The thermal structural component as defined in  claim 3 , wherein the ratio is at most about 0.06:4. 
     
     
         5 . The thermal structural component as defined in  claim 1 , wherein a width of the narrow necks is at most 0.1 inches. 
     
     
         6 . The thermal structural component as defined in  claim 1 , wherein at least some of the apertures are polygonal shaped and each include first flat sides extending parallel the spaced flanges, and include second flat sides extending at an angle to the spaced flanges. 
     
     
         7 . The thermal structural component as defined in  claim 6 , wherein the angle is between about 45 and 60 degrees. 
     
     
         8 . The thermal structural component as defined in  claim 1 , wherein the apertures are a repeating pattern of triangular shapes positioned in alternatingly inverted positions. 
     
     
         9 . The thermal structural component as defined in  claim 1 , wherein the apertures are a repeating pattern of quadrilateral shapes positioned in alternatingly inverted positions. 
     
     
         10 . The thermal structural component as defined in  claim 1 , wherein the necks are elongated and define a narrowed length of at least about 0.25 inches long. 
     
     
         11 . The component defined in  claim 1 , wherein at least one of the center web and flanges further includes small holes for receiving fasteners, such as nails or screws, for securing the component to another structure. 
     
     
         12 . A building wall frame comprising:
 a plurality of thermal structural components as defined in  claim 1 , the components being spaced apart but arranged to define a wall; and   a plurality of structural insulated panels extending between the components, the panels having edges engaging the center webs of adjacent components and including front and rear faces engaging an inside of the flanges of the components, the insulated panels engaging the thermal structural components to stabilize the thermal structural components in the wall arrangement.   
     
     
         13 . A thermal structural component comprising:
 a metal structural beam component having a center web and spaced flanges forming one of an I-beam shape, channel shape, or a C-beam shape, the center web including apertures spaced along the center web that define therebetween a series of narrow necks of material located in an outer 25% of the center web, the series of narrow necks being located at alternating ends of the center web and minimizing thermal conductivity between the spaced flanges, but the narrow necks being longitudinally misaligned and located near the spaced flanges to prevent forming a weak longitudinally-extending fold line in the beam component such that a strength of the beam component is substantially maintained.   
     
     
         14 . The thermal structural component as defined in  claim 13 , wherein the necks have a first width, and the center web has a second width, a ratio of the first width to the second width being at most about 0.25:4. 
     
     
         15 . The thermal structural component as defined in  claim 14 , wherein the ratio is at most about 0.1:4. 
     
     
         16 . The thermal structural component as defined in  claim 13 , wherein at least some of the apertures are polygonal shaped and each include first flat sides extending parallel the spaced flanges, and include second flat sides extending at an angle to the spaced flanges. 
     
     
         17 . The thermal structural component as defined in  claim 13 , wherein the apertures are a repeating pattern of triangular shapes positioned in alternatingly inverted positions. 
     
     
         18 . The thermal structural component as defined in  claim 13 , wherein the apertures are a repeating pattern of quadrilateral shapes positioned in alternatingly inverted positions. 
     
     
         19 . The component defined in  claim 13 , wherein at least one of the center web and flanges further includes small holes for receiving fasteners, such as nails or screws, for securing the component to another structure. 
     
     
         20 . A thermal structural component comprising:
 a metal structural beam component having a center web and spaced flanges forming one of an I-beam shape, channel shape, or a C-beam shape; the center web including apertures spaced longitudinally along the center web that define therebetween a series of narrow necks of material, adjacent ones of the narrow necks defining a fold line that is at least 45 degrees angled to a length of the stud, the apertures with narrow necks substantially minimizing thermal conductivity between the spaced flanges, but the narrow necks being longitudinally misaligned to prevent forming a weak longitudinally-extending fold line that extends parallel the length of the beam component, such that the arrangement substantially maintains the strength of the beam component.   
     
     
         21 . The component defined in  claim 20 , wherein at least one of the center web and flanges further include small holes for receiving fasteners, such as nails or screws, for securing the component to another structure. 
     
     
         23 . A thermal structural component comprising:
 a metal structural beam component having a center web and spaced flanges forming one of an I-beam shape, channel shape, or a C-beam shape; the center web including a series of repeated apertures, some inverted from others and each spaced longitudinally along the center web, with sections of material remaining in the center web defining therebetween a series of triangular truss-simulating sections of material extending between edge portions of the center web.   
     
     
         24 . A thermal structural component comprising:
 a metal structural beam component having a center web and spaced flanges forming one of an I-beam shape, channel shape, or a C-beam shape; the center web including apertures that define alternatingly positioned narrow necks that minimize heat transfer but maintain structural strength of the beam component.   
     
     
         25 . The component defined in  claim 24 , wherein the necks have a width of less than about 0.1 inches.