Passive House Sub-Framing Systems

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/546,225, filed on Oct. 29, 2023.

BACKGROUND OF THE INVENTION

Field of Invention

The present invention relates primarily to novel and useful sub-framing systems for improved thermal performance of building exteriors, and which combines insulation types to increase structural capacity.

Description of Related Art

There are numerous thermal clips and sub-framing systems which may be used for thicker insulation in Passive House applications, but very few, if any, are able to support significant static loads because of the cantilevered loads through much thicker insulation than common buildings. Generally speaking, traditional insulation thickness are seldom over 6″ thick, whereas Passive House applications may be as thick as 24″.

This invention will provide a means to accommodate these thicker insulation applications and provide the static load support required for mounting most cladding types. At the same time, Passive House Sub-Framing Systems will allow for combustible high-thermal performance rigid insulation to be used in combination with medium density insulation which are best for fire protection. In addition, Passive House Sub-Framing Systems provides a means to install weather barrier materials much farther away from the structural framing of the building, or as a secondary weather barrier layer in addition to the layer at the sheathing of the building with periodic drain ports between weather barrier layers. The unique thermal brackets used for Passive House Sub-Framing Systems are mounted to vertical structural framing members such as steel and wood studs, yet have a unique ability to directly support horizontally or vertically mounted sub-girts and/or base profiles for cladding mounting system support.

SUMMARY OF THE INVENTION

In accordance with the present application, novel and useful Passive House Sub-Framing Systems are herein provided including two basic variations including a formed wire bracket system which may support sub-girts mounted in any orientation parallel with a wall, and a fabricated sheet variation which may also support sub-girts in any orientation parallel to a wall. This system may utilize thermal isolators in a number of locations, will utilize multiple compression stabilizers which may be mounted in numerous directions and attached to the thermal brackets, a bottle-opener shaped tab positioning tool, and fiber reinforced sub-framing profiles which may also be mounted in numerous directions on the thermal brackets.

Formed wire based Passive House Sub-Framing Systems' thermal brackets are made of stainless-steel wire which comes in coil form and ran through an automated wire forming machine which is programmed to consistently make the individual desired shape(s) in a continuous process. Wire formed brackets easily penetrate into rigid insulation. Fabricated sheet Passive House Sub-Framing Systems' thermal brackets, as well as compression stabilizers for either iteration, are made of metal sheet, such as galvanized steel of any desired grade. These components are made from steel sheet may be fabricated using a turret press and brake press, with the turret press creating the flat patterns and a brake press to form those flat patterns. 3d printing is another option of manufacture of these profiles and shapes, and which may incorporate the use of other materials including continuous fiber reinforced plastics.

Rigid high-density polyethylene (HDPE) or stainless steel bonded to flexible neoprene materials may be used as thermal isolators. HDPE may be manufactured via injection molding, while stainless steel bonded to neoprene is a laminated product in sheet form which is then formed to the desired shape(s) on a turret press to create the final parts. These thermal isolators attachment hole locations will match the attachment hole locations of the thermal brackets of this invention.

The tab positioning tool is shaped like traditional bottle openers, with a handle on one side and a finger (one or more) beyond the handle which fits into a bend slot of a tab. An arm which extends beyond the finger is then used to push the top of the tabs in a cantilever fashion to bend to the desired angle. Using a hammer may complete the angle. Tab positioning tools are made of steel using 3D printers or formed from a turret and/or brake press operations.

Passive House Sub-Framing Systems provides for unique products and an installation process which is what allows for a much higher static load capacity compared to any other thermal bracket and sub-girt assembly currently available. Thermal isolators are used between the thermal brackets and weather barrier (aka WRB, if any) at the structural wall substrate where the thermal brackets are installed with their attachment holes parallel with the vertical structural studs. Rigid insulation, such as foam board or high-density rock mineral wool insulation are installed over the existing WRB in a thickness such as 4″ (101.6 mm). Thermal brackets made of wire possess loops at the same intervals as the thicknesses of the insulation which allow a compression stabilizer, such as an angle, to be pressed onto the first layer of insulation and then have a fastener pass through the loop in the wire and into the compression stabilizer to fix the insulation in place. Metal sheet formed thermal brackets have built-in tabs which may be bent over to compress and embed into the rigid insulation to fix the insulation in place via the bend strength of the metal. These tabs may have small protrusions extending from them, which is a tab created during the turret press process using special punches and dies. In addition to the tabs fixing the insulation in place, Compression stabilizers may also be passed through a hole in the thermal bracket created when the tabs are bent over, and the compression stabilizers may be fixed to the tabs (or directly to the thermal bracket) via mechanical fastening such as with self-drilling screws. The compression stabilizers place an additional level of compression on the insulation to hold it in place and effectively stabilize the thermal brackets in whatever direction the Compression Stabilizers are positioned, which typically will be vertically or horizontally, although diagonally in any direction is possible. These Compression Stabilizers are intended to minimize gaps between slabs of rigid insulation by compressing slightly into the insulation. As an example, the tabs disclosed, if used with 4″ rigid insulation, would be hinged at just less than 3- 15/16″ so that when they are bent into vertically oriented insulation they are embedded into the insulation. Subsequent Compression Stabilizers which are also mounted vertically may then be pushed into the insulation and mechanically fastened to both the tab and sheet thermal bracket to permanently fix it in place. This process repeats for all subsequent rigid foam insulation each extending another 4″ away from the structural framed wall or substrate. In this example, if 24″ of insulation is required, there will be 5 layers of rigid insulation installed which accounts for 20″ of insulation. The 5^th layer of rigid insulation may be foil faced for heat deflection, for benefits of adhering another WRB coating to it such as fluid applied or peel and stick types, and/or for using adhesive coverings over the insulation butt joints to keep air, water and moisture protection as far away from the structural wall as possible. The final or 6^th layer of insulation may be medium density rock mineral wool insulation to provide fire protection of the complete wall assembly. Rock mineral wool may also be used for all 6 layers of insulation over windows, doors and other openings for fire protection, with a thin sheet of formed steel attached to and extending down vertically from the location of the 5^th layer of rigid insulation above, then turning 90 degrees into the opening (with a drip edge) so that the outer WRB may be continuous between the rigid and medium density insulation. The 6^th layer (which may be 7 layers if there are say 2 layers of 4″ medium density insulation used) of medium density insulation will extend continuously as required and is supported by a sub-girt of preference such as a steel or GFRP Z-shape or adjustable clip and rail system, whatever is required to support the intended cladding(s). All insulation may be brick-layed in orientation, alternating vertically and horizontally to avoid gaps which extend from the exterior to the interior. The fully assembled Passive House Sub-Framing Systems is now ready for installation of the intended cladding type and system.

It may be apparent that novel and useful Passive House Sub-Framing Systems has been hereinabove described which works, is used, and the method of installations are in a manner not consistent with conventional products and methods, and unlike what is taught in prior art.

It is therefore an object of the present Passive House Sub-Framing Systems to provide lightweight, resilient, inexpensive, and easy to use Passive House Sub-Framing Systems.

Another object of Passive House Sub-Framing Systems is to provide extreme thermal performance coupled with extreme static load capacity.

Another object of Passive House Sub-Framing Systems is to provide thermal bracket vertical and horizontal support at various distances away from any orientated substrate.

A further object of Passive House Sub-Framing Systems is to provide multiple means of fixing insulation of various types together or independently of each other.

Another object of Passive House Sub-Framing Systems is the provision of a means to add an additional weather barrier to the outside of the insulated Passive House Sub-Framing Systems assembly, or to completely replace the WRB at the structural wall assembly.

A further object of Passive House Sub-Framing Systems to provide drainage via adhered tubes, anywhere from within the insulation layers to the exterior of the system.

Another object of Passive House Sub-Framing Systems is to provide means to easily transition from vertically mounted thermal brackets to horizontally mounted sub-girts.

A further object of Passive House Sub-Framing Systems is to provide Compression Stabilizers which may be oriented and used to direct water towards the exterior of Passive House Sub-Framing Systems assembly.

A further object of Passive House Sub-Framing Systems is to provide the use of adhesives (including foam types) as thermal breaks, insulators and bond-breakers anywhere within the system, including between metal parts and between insulation slabs, which may also tie insulation slabs together as a single slab of rigid insulation.

Another object of Passive House Sub-Framing Systems is to provide combinations of materials to make a single thermal bracket, such as stainless steel near the structural wall to be used for lower thermal transfer properties, and carbon steel near the sub-girt location for easier attachment properties (such as drilling through), where the two materials are combined using a mechanical fixing means such as clinching.

Another objective is to provide a circuitous path within the thermal brackets, created by the open areas around tab locations, which forces heat to take a longer path which provides more opportunity to transfer energy into the adjacent insulation.

Another objective is to provide tabs in the sheet thermal brackets which may open in any direction, not just over the top of the insulation, and where any surface of the tab may be used to help fix the insulation in place temporarily or permanently.

Another objective is to provide holes, slots and other apertures in sheet thermal brackets in any location and which may be used for any purpose including allowing for thermal movement and/or fixing of other adjacent and affixed components such as Compression Stabilizers and/or Insulation Struts, and sub-girts and/or base profiles for cladding systems.

A further objective is for Passive House Sub-Framing Systems to provide a grid-like structural system within the insulation layers by using Compression Stabilizers as well as exterior of the insulation using sub-girts for optimum structural performance, spreading loads out among as much of the rigid insulation as possible.

Another objective is for Passive House Sub-Framing Systems'formed wire brackets, although only one is shown, is to have single or multiple attachment loops extending beyond the first loop and located at each insulation layer, with one or more windings each loop, strategically positioned to allow for insertion of fasters to fix to Compression Stabilizers, Insulation Struts, sub-girts and other components, The attachment loops may oriented in any direction along the length of the formed wire bracket to affix to Compression Stabilizers.

Another objective is for use of WRB materials between any of the insulation layers and/or at varying and intermixed insulation depths.

Another objective is to utilize the structural properties of Passive House Sub-Framing Systems as a grid, connected directly to the structural stud and track of the wall to eliminate and replace sheathings traditionally used at the exterior of the structural framing wall. With the WRB in close proximity to the cladding materials, the innermost WRB layer(s) is also eliminated.

The invention possesses other objects and/or advantages especially as concerned to particular characteristics and features thereof which will become apparent as the specification continues. Variations of the invention, individual parts or components of its'parts or features, may be combined to make new variations with benefits.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description of the invention, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, exemplary constructions of the invention are shown in the drawings. However, the invention is not limited to the specific structures disclosed herein. The description of a structure referenced by a numeral in a drawing is applicable to the description of that structure shown by that same numeral in any subsequent drawing herein.

FIG. 1 is a 3D isometric elevation view of the preferred formed wire thermal bracket with a single loop for a single layer of rigid foam insulation.

FIG. 2 is a 3D isometric elevation view of an alternate formed wire thermal bracket with an additional stabilizing leg. As with the preferred iteration of FIG. 1, wire formed brackets may penetrate the middle of rigid insulation slabs more easily because of their small profiles having limited portions extending through the insulation, allowing the insulation to more easily “self-heal” around these thermal brackets.

FIG. 3 is a 3D isometric side elevation view of the thermal bracket of FIG. 2.

FIG. 4 is a 3D isometric plan view of the thermal bracket of FIG. 2.

FIG. 5 is a 3D isometric side elevation view of a modified iteration of the thermal bracket of FIG. 2 having more than one attachment loop.

FIG. 6 is a 3D isometric plan view of a steel stud back-up wall with FRP sheathing adhesively applied to it and used as both the weather barrier and sheathing, and having taped, structurally caulked or otherwise sealed seams and fasteners. Thermal brackets of FIG. 1 are then mounted through the FRP sheets with fasteners and an adhesive sealant to prevent leaks.

FIG. 7 is a 3D isometric elevation view of the attachment of thermal brackets of FIG. 6 in a close-up view near a covered FRP sheathing joint.

FIG. 7-B is a 3D isometric section view of a vertical or horizontal FRP sheathing H-shaped splice. The adhesive applied over the top allows for thermal expansion with or without adhesives also added into the slots of the H-shaped splice prior to FRP sheathings being inserted into them. Of course, the FRP sheets may be of any other material such as steel.

FIG. 8 is a 3D isometric plan-section view of the wall of FIG. 6 having rigid insulation installed and showing the attachment holes of the thermal brackets of FIG. 1 penetrating through the middle of the rigid insulation. The rigid insulation is sealed at all seams to provide a sealed weather barrier.

FIG. 9 is a 3D isometric elevation view of the attachment hole of the thermal bracket of FIG. 8 in a close-up view. Sealants/adhesives may then be applied over and around the exposed portion of the thermal bracket before and/or during installation of sub-girts.

FIG. 10 is a 3D isometric plan view of the wall of FIG. 8 with sub-girts installed over the top of the sealed rigid insulation which is also acting as the weather barrier.

FIG. 11 is a 3D isometric plan view of the assembly of FIG. 10.

FIG. 12 is a 3D isometric plan view of the wall assembly of FIG. 10 having medium density insulation being installed over the top of the rigid insulation layer.

FIG. 13 is a 3D isometric elevation view of an insulation strut installed through a sub-girt of FIG. 12 to hold the medium density insulation tightly against the rigid insulation.

FIG. 14 is a 3D isometric elevation view of the completed wall assembly of FIG. 12 which is ready for the installation of any cladding system assembly.

FIGS. 15 and 16 are 3D isometric elevation views of both sides of the preferred formed sheet thermal bracket.

FIGS. 17 and 18 are 3D isometric elevation views of both sides of the preferred formed sheet thermal bracket with the tabs bent out as if embedded into insulation. The butterfly attachment flange is bent as well to provide equal amounts of metal on both sides of the bend location to prevent the flange from moving when drilling into or otherwise adding force to one side of the butterfly attachment flange when the sub-girt or cladding system profile spans across it an other thermal sheet formed thermal brackets.

FIG. 19 is a 3D isometric elevation view of the bent butterfly attachment flange of FIGS. 17 and 18 in a close-up view.

FIG. 20 is a 3D isometric elevation view of an alternate butterfly attachment flange for sheet formed thermal brackets.

FIG. 20-B is a 3D isometric elevation view of an alternate sheet formed thermal bracket having the butterfly attachment flange positioned to the side of the thermal bracket instead of on top of it, which similarly allows for vertical, horizontal or diagonal positioning of sub-girts, and when in multiple locations a means to support insulation at different depths of the sheet formed thermal bracket.

FIG. 21 shows a 3D isometric plan section view of a wall assembly from the sheathing through the semi-rigid insulation layer.

FIG. 22 shows a 3D isometric section view of a horizontally mounted FRP sub-girt/sheathing/weather barrier system attached to the butterfly attachment flange of the vertically mounted preferred formed sheet thermal bracket.

FIG. 23 shows a 3D isometric close-up section view of FIG. 22.

FIG. 24 shows a 3D isometric elevation view of another sheet formed thermal bracket having a triangulated shape.

FIG. 25 shows a 3D isometric plan stepped-section view of the rigid insulation layers through an alternate FRP J-shaped sub-girt, and having each layer sealed independently from the next.

FIG. 26 shows a 3D isometric plan stepped-section view of FIG. 25 in close-up to better see the structure of the FRP J-shaped sub-girt.

For a better understanding of the invention of this application, reference is made to the following detailed description of the preferred embodiments thereof which should be referenced to the prior described drawings.

DETAILED DESCRIPTION OF THE INVENTION

Various aspects of the present application will evolve from the following detailed description of the preferred embodiments thereof which should be taken in conjunction with the prior described drawings.

Before explaining the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the construction and arrangement of parts illustrated in the accompanying drawings. The invention is capable of other embodiments, as depicted in different figures as described above and of being practiced or conducted in a variety of ways. It is to be understood that the phraseology and terminology employed herein is for the purpose of description and not of limitation.

It should be understood that an embodiment is an example of a possible implementation of any features and/or elements presented in the attached claims. Some embodiments have been described for the purpose of illuminating one or more of the potential ways in which the specific features and/or elements of the attached claims fulfil the requirements of uniqueness, utility and non-obviousness.

Use of the phrases and/or terms such as but not limited to “exemplary embodiment,” “an embodiment,” “an alternate embodiment,” “one embodiment,” “another embodiment,” or variants thereof do not necessarily refer to the same embodiments. Unless otherwise specified, one or more particular features and/or elements described in connection with one or more embodiments may be found in one embodiment, or may be found in more than one embodiment, or may be found in all embodiments, or may be found in no embodiments. Although one or more features and/or elements may be described herein in the context of only a single embodiment, or alternatively in the context of more than one embodiment, or further alternatively in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any features and/or elements described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.

For the purposes of the description, a phrase in the form “A/B” or in the form “A and/or B” or in the form “at least one of A and B” means (A), (B), or (A and B), where A and B are variables indicating a particular object or attribute. When used, this phrase is intended to and is hereby defined as a choice of A or B or both A and B, which is similar to the phrase “and/or”. Where more than two variables are present in such a phrase, this phrase is hereby defined as including only one of the variables, any one of the variables, any combination of any of the variables, and all of the variables, for example, a phrase in the form “at least one of A, B, and C” means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C).

It is to be understood that the term “comprises” and grammatical equivalents thereof are used herein to mean that other components, ingredients, steps, etc. are optionally present. For example, an article “comprising” (or “which comprises”) components A, B, and C can consist of (i.e., contain only) components A, B, and C, or can contain not only components A, B, and C but also contain one or more other components.

Reference will now be made in detail to preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.

While the foregoing embodiments of the application have been set forth in considerable particularity for the purposes of making a complete disclosure of the invention, it may be apparent to those of skill in the art that numerous changes may be made in such details without departing from the spirit and principles of the application. Additionally, combinations and interchangeability or inter-use of components and embodiments should be considered apparent to the spirit and principles of the application, and in which all terms are meant in their broadest, reasonable sense unless otherwise indicated. Any headings utilized within the description are for convenience only and have no legal or limiting effect.

Embodiments of the invention are identified by an upper-case letter and elements of the invention are identified by reference character 10.

With reference to FIG. 1, preferred formed wire bracket A is shown having first loop 10, which creates first fastener hole 12, and then extends into separator leg 14 which terminates into second loop 16, which creates second fastener hole 18, which then terminates at substantially perpendicular first arm 22 at bend 20. First arm 22 extends terminates at offset bend 24 which extends into third loop 28 which creates third fastener hole 26. Third loop 28 may continue 360 degrees and extend to other substantially perpendicular arms (not shown) which are parallel to first arm 22 in order to support further layers of insulation (not shown).

FIGS. 2 and 3 show an alternate formed wire bracket embodiment A-2 having a first mounting hole 28 which terminates into substantially perpendicular arm 30, which terminates at jog 32. Jog 32 extends into 180-degree single fastener loop 34 which terminates at diagonal bend 36, which then extends into diagonal leg 38 which is substantially in-plane with perpendicular arm 30, which then extends into second mounting hole 40 which is in alignment with and bent (at a bend shown but not numbered) to be in plane with first mounting hole 28.

FIG. 4. Shows formed wire bracket embodiment A-2 from an alternate angle to show the alignment and planarity of perpendicular arm 30 (not numbered) and diagonal leg 38 (not numbered) as well as first mounting hole 28 (not numbered) and second mounting hole 40 (not numbered).

FIG. 5 shows alternate embodiment A-3, which is identical to alternate embodiment A-2, except having multiple 360-degree loops 42 in lieu of single fastener loop 34.

FIG. 6 shows a steel stud wall (not labeled as an assembly) having FRP sheathing 44 attached to studs 46 using adhesives (not shown), and wire brackets A are installed in numerous locations along each stud and in alignment with each other horizontally, and mechanically fastened (not shown in this drawing) through FRP sheathing 44, adhesives (not shown) and into studs 46. FRP sheathings 44 are flat sheets, and the edges of the FRP sheathings 44 terminate into a H-shaped FRP pultrusions (not shown here) on all sides in such a manner as to make a continuous FRP weather barrier and sheathing across large wall spans (not shown). Structural caulk 48 then covers the seams (not shown here), which are all FRP sheathings 44 edges inserted inside FRP H-shapes (not shown here). FRP H-shapes (not shown here) may take other forms such as a combination Land H shape (not shown) to accommodate locations such as inside and outside corners of buildings (not shown), or a C shape (not shown) for termination ends where the FRP sheathings 44 end in a wall assembly. These FRP H-shapes provide rigidity to the FRP sheathings 44 edges (not shown) so that the FRP sheathings 44 edges (not shown) do not necessarily have to terminate over a structural member such as studs 46.

FIG. 7 shows a close-up view of wire formed bracket A mechanically fastened through FRP sheathings 44, adhesives (not shown) and into studs 46 (not shown here) using mechanical fasteners 50.

FIG. 7-B shows FRP H-shape I with FRP sheathings 44 inserted into slots 47 and 49 and having adhesive/sealant 45 fully covering the entire splice to allow for thermal movement without compromising the integrity of the splice. H-shape I is comprised of at two slots 49 which are surrounded by arms 51 on each side and middle 53 on one end. This H-shape may also be an L shape for inside and outside corners of buildings, or T-shaped with 3 slots, t-shaped with more than 3 slots, etc. as needed for all building conditions.

FIG. 8 shows rigid insulation slab 52 adhesively adhered (not shown) to FRP sheathings 44, impaled over wire formed brackets A. Rigid insulation seam 54 contains adhesive (not shown) between rigid insulation slabs 52, and sealed seam 56 which is comprised of an approved commercially available tape or other sealant material.

FIG. 9 shows a close-up of wire formed bracket A penetrated through rigid insulation slabs 52, where rigid insulation 52 self-heals and wraps back around wire formed bracket A.

FIG. 10 shows sub-girts 58 mounted parallel with studs 46 and spanning across sealed seams 56. Sub-girts 58 may also be mounted perpendicular to studs 46 orientation when third loop 28 and therefore fastener hole 26 are manufactured to match.

FIG. 11 shows that sub-girts 58 are manually pressed down 60 (indicated by blue directional arrow) to tightly abut rigid insulation 52, then mechanical fasteners 62 are installed fastener hole 26 (not labeled) and into sub-girts 58 to permanently fix them in place. Sub-girts 58, tightly abutted to rigid insulation 52, utilizes the compressive strength of the rigid insulation 52 to provide stiffness to formed wire brackets A, not allowing them to easily move, and substantially allowing formed wire brackets A to be used for pull-out strength (not shown). Although Z-shaped sub-girt 58 is shown, h-shapes (not shown) and others may be used and drilled out to fit over formed wire bracket A locations for additional pull-over strengths (not shown) against rigid insulation 52 and on all sides of wire formed brackets A. Immediately prior to sub-girts 58 being installed over rigid insulation 52, adhesive sealants are placed into and around the penetration locations (not numbered) of wire formed brackets A to prevent leaks at those locations and to seal and adhere between wire formed brackets A, sub-girts 58 and insulation 52.

FIG. 12 shows medium density insulation 64 being placed under sub-girts 58 and adjacent to rigid insulation 52 in a rotating while inserting fashion 66 (indicated by curved directional arrows) to form a subsequent gap-free fire protection insulation layer(s).

FIG. 13 shows a close up of the installed sub-girts 58 and medium density insulation 64 with insulation struts B installed onto sub-girt 58 and into medium density insulation 64. Insulation Strut B is installed to sub-girt 58 by inserting curved end 68 through hole 70 of sub-girt 58, then feeding finger 72, bend 76 and arm 74 through hole 70 until attachment leg 78 is adjacent to sub-girt 58. Lock washers 72 are installed onto both curved ends 68. Insulation strut B is then rotated 80 (indicated by circular directional arrow, and in this case counter-clockwise) into medium density insulation 64 on both sides of sub-girt 58 until lock washers 72 are firmly pressed onto medium density insulation 64. Fastener 82 is then installed through attachment leg 78 and into sub-girt 58, with rotated 80 pressure provided to ensure a tight fit to insulation 64.

FIG. 14 shows an elevation view of a completed wall assembly ready for cladding system installation.

FIGS. 15 and 16 show sheet formed bracket C consists of attachment flange 81 having attachment holes and slots 83 and terminating at substantially perpendicular bend 84, which extends into body 100. Body 100 further consists of multiple bendable tabs 86 which are created via punched areas 88 and notches and slots 90 at any location(s) on body 100. Bend locations 92 may or may not have notches and slots 90 in the middle of them, which is dependent on the length of bend locations 92 and the amount of radius (not shown) and bend strength (not shown) desired at bend locations 92 when tab 86 is bent. Holes and slots 94 may be used to assist in the attachment of insulation struts (not shown here), compression stabilizers (not shown here), or other hardware (not shown here). Dual bend locations 96 are used at butterfly attachment flange 98 locations to provide greater static load strengths and allow for the dual cantilevered butterfly attachment flange 98 when bent.

FIGS. 17 and 18 show all tabs 86 bent out in opposite directions from body 100, in no particular pattern. Butterfly attachment flange 98 cantilevers to both sides of body 100, and may be used in lieu of tabs 86 for the height of body 100 when desired.

FIG. 19 shows a close up of butterfly attachment flange 98.

FIG. 20 shows bendable termination tabs 102 and 106 extending in opposite directions from body 100 at bend locations 104 and 108 respectively. Termination tabs 102 and 106 may then be attached to vertical or horizontal sub-girts (such as hat channels, not shown) which has flanges (not shown) on each side, one flange (not shown) attaching to termination tab 102 and the other flange (not shown) attaching to termination tab 106.

FIG. 20-B shows alternate sheet formed bracket C-2 which is almost identical to sheet formed bracket C, but having a perpendicular butterfly attachment flange (not numbered) in relationship to the body (not numbered) which may attach to horizontally mounted sub-girts (not shown). Holes and slots (not numbered) near and on the perpendicular butterfly attachment flange (not numbered) allow sheet formed bracket C-2 to be attached to sub-girts (not shown) vertically as well when perpendicular butterfly flange (not numbered) is not bent and remains in plane with the body (not numbered).

FIG. 21 shows multiple sheet formed brackets C attached through sheathing 44. Rigid insulation 52 are installed between sheet formed brackets C at multiple levels to show tabs 86 bent once rigid insulation 52 are installed and when Compression Stabilizers D are installed through the openings of bent tabs 86, and then mechanically fastened (not numbered) to bent tabs 86 to solidify a grid pattern (not labeled), connecting all sheet formed brackets C together while compressing slightly onto rigid insulation 52. Weather barrier 110 is partially shown between rigid insulation 52 and medium density insulation 64, with medium density insulation 64 also resting on top of bent sheet formed bracket C's butterfly attachment flange 98. As shown to the bottom right of the drawing, tabs 86 may remain in plane with the body (not numbered) of sheet formed bracket C until rigid insulation 52 is installed and requires tab 86 to be bent to hold it in place or provide structural support (not indicated) to sheet formed bracket C.

FIG. 22 shows a close-up of a sheet formed bracket C of FIG. 21 in a section view showing an FRP sub-girt F and sheathing/weather barrier E, and having a generally indicated cladding mounting system and cladding 112 attached to FRP sub-girt F.

FIG. 23 better shows FRP sub-girt F being comprised of, on mirrored sides of center 124, outer slots 114 and inner slots 116 are created by H-shape 113. H-shape 113 extends one of 4 legs (not numbered) to perpendicular center 124 from both mirrored sides. Center 124 extends outwards and branches off at a designated location (not specified) along its length perpendicularly to arm 126 for a short distance, which terminates at another perpendicular bend (not numbered) which then continues as finger 128 which is parallel to center 124 until center 124 and finger 128 terminate at ends (not numbered) substantially equal to each other in length at termination point (not numbered), and which creates slot 130 between them. Slot 130 may be filled or partially filled with adhesive (not shown) to help eliminate air gaps and thermal losses. Generally indicated cladding mounting system and cladding 112 has a component (not numbered) adjustably inserted into slot 130 and fixed via mechanical fasteners 132. Adhesives (not shown) cover locations where sheathing/weather barriers E are inserted into outer slots 144 and may be introduced into outer slots 114 prior to sheathing/weather barrier E's insertion into them. Steel sheet strips 120 have ends 118 which are rotationally positioned into inner slots 116 and fixed to sheet formed bracket C's butterfly attachment flange 98. FRP sub-girt F is shown mounted perpendicular to sheet formed bracket C in this drawing.

FIG. 24 shows alternate sheet formed bracket C-3 comprised of triangular shaped body 134 to reduce thermal transfer, consisting of notches 136 and slots 150 which assist in keeping bend locations (not shown) when tabs 138 and 144 are bent over (not shown here). Tip 140 is designed to penetrate through rigid insulation (not shown here) layer upon layer. Gaps 142, 148 and 152 provide locations for insulation (not shown) to fill into and create a block for thermal transfer, including radiated thermal transfer (not shown), as well as creating a circuitous path to redirect heat transfer from reaching the substrate. Gussets 154 help stiffen sheet formed bracket C-3 laterally, and perpendicular base 158 has holes and slots 156 where required for attachment and positioning when fastened to substrates, as well as to allow for male appendages of thermal and acoustic isolators 160 to insert into for temporary fixing.

FIG. 25 shows an installed sheet formed bracket C-3 with tabs 144 extended over rigid insulation slabs 52 and having weather barriers 110 installed over each rigid insulation 52 layer. J-shaped FRP sub-girt H is pressed down onto rigid insulation 52 before being mechanically fastened (not shown here) to sheet formed bracket C-2, abutting tightly against rigid insulation 52 to provide significantly additional static load support to sheet formed bracket C-2.

FIG. 26 shows J-shaped FRP sub-girt H comprising J-slots 168 in 2 places to accommodate steel angle 162 which is open beyond 90 degrees (such as 95 to 100 degrees). Angle 162 is inserted on one end (not numbered) into one J-slot 168 so that the opposite end (not numbered) remains outside of the opposite J-slot 168. The flange (not numbered) of angle 162 on the installed end (not numbered) is pushed into gap 176 and against leg 174 of J-shaped FRP sub-girt H which causes the opposite flange (not numbered) and the other end (not numbered) of angle 162 to slide completely inside of J-shaped FRP sub-girt H and other J-slot 168, with the opposite flange (not numbered) and other end (not numbered) now adjacent to the inside of arm 172 of J-shaped FRP sub-girt H. When angle 162's flange (not numbered) which is adjacent to leg 174 is released, tension in angle 162 caused by the compression releases (not shown) causing the opposite end (not numbered) to enter second J-slot 168 of J-shaped FRP sub-girt H, permanently fixing angle 162 in place and recreating gap 176. Base 170 is the surface of J-shaped FRP sub-girt H which contacts rigid insulation 52. Medium density insulation 64 are installed on top of rigid insulation 52 and weather barrier (not numbered here).