Wood building studs with an outboard foam insulation thermal barrier and method of manufacture

Abstract

A conventional dimensioned wood building board have an outbound edge that has been incised and with some crown remediation. An even outboard foam insulation barrier layer is applied to the incised outboard edge of the board. A method for manufacturing multiples of these insulated wood building boards in an assembly line includes compressing the crown out of the side outbound edge of the boards, incising the crown side edge of the boards, applying an even thickness layer of outbound foam insulation to keep the boards within the dimension of conventional lumber, separating the boards and sanding to finish the wood boards with outboard foam insulation.

What is claimed: 
     
         1 . An insulated dimensional 2×6 inches, 2×8 inches, 2×10 inches, 2×12 or 2×14 inch wood boards made from dimensional 2×4 inch, 2×6 inch, 2×8 inch, 2×10 inch or 2×12 boards for walls, roofs and floors of houses and commercial buildings, the insulated stud comprising:
 a.) the outbound edge being incised to increase surface area thereof; and 
 b.) a uniform 1½-2½ inch square liquid urethane foam insulation is bonded to the outboard incised thereby creating insulated dimensional lumber of 2×6 inches, 2×8 inches, 2×10 inches 2×12 inches or 2×14 inches. 
 
     
     
         2 . The insulated dimensional wood boards of  claim 1 , wherein the outboard are incised up to ⅛ inches into the outboard edges as to not damage any wood fibers. 
     
     
         3 . The insulated dimensional wood boards of  claim 1 , wherein the wood boards have their crowns mitigated by pressure force to assure the urethane foam insulation is uniform in 1½-2½ inch thickness. 
     
     
         4 . The insulated dimensional wood boards of  claim 1 , wherein the wood boards are heated to approximately 100° F. to assure bonding of the urethane foam insulation and minimize the amount of liquid urethane foam used. 
     
     
         5 . An assembly line for simultaneously manufacturing multiple evenly insulated dimensional boards of 2×6 inches, 2×8 inches, 2×10 inches 2×12 inches or 2×14 inches for walls, roofs and floors of houses and commercial buildings, comprising:
 a.) a board placement station for dimensional 2×4 inches, 2×6 inches, 2×8 inches, 2×10 inches or 2×12 inch wood boards with their outboard crowned edges facing upwards; 
 b.) a vertical compression station for temporarily removing the crowns from the boards and hold the boards down once compressed; 
 c.) an infrared heater station to warm the boards; 
 d.) a two part urethane injection station followed immediately by a mold station to coat the boards and contain the expanding urethane under compression; 
 e.) a urethane saw station to cut the urethane only and free the insulated dimensional boards; and 
 f.) a sanding station to smoothly sand the boards with urethane thereon. 
 
     
     
         6 . A method for simultaneously manufacturing multiple evenly insulated dimensional boards of 2×6 inches, 2×8 inches, 2×10 inches 2×12 inches or 2×14 inches for walls, roofs and floors of houses and commercial buildings, comprising:
 a.) stacking the boards face-to-face with the boards' outboard crowned edges facing upwards; 
 b.) vertical compressing the outboard crowned edges downwardly temporarily removing the crowns from the boards and holding the boards down once compressed; 
 c.) heating the boards to approximately 100° F.; 
 d.) injecting two part urethane onto the outboard edges and passing the boards into a mold to guide and compress the curing urethane; 
 e.) sawing the urethane parallel to the boards to separate the boards; and 
 f.) sanding the urethane and boards to making the boards and urethane smooth.