INSULATED PANEL

• US 20100043327A1
• Filed: 08/19/2009
• Published: 02/25/2010
• Est. Priority Date: 08/19/2008
• Status: Active Grant

• Current Assignee: Jordan Byron Rothwell
• Original Assignee: Jordan Byron Rothwell
• Inventors: Rothwell, Jordan Byron
• Granted Patent: US 8,365,497 B2
• Time in Patent Office: Days
• US Class Current: 52/309.400
• CPC Class Codes: E04C 2/205 of foamed plastics, or of plastics and foamed plastics, optionally reinforced
• CPC Class Codes: E04C 2/386 with a frame of unreconstituted or laminated wood

Abstract

The insulated panel comprises exterior sheathing, studs, rigid foam panels and a spray-pour foam. The rigid foam panels are placed up against the sheathing between the studs, and the spray-pour foam is used to fill in the voids.

Claims

1. An insulated panel comprising:

a pair of spaced apart studs;

sheathing secured to the studs;

a first rigid foam panel adjacent the sheathing and between the studs; and

a spray-pour foam cured in place adjacent the first rigid foam panel and between the studs.

2. The insulated panel of claim 1, wherein a second rigid foam panel is located adjacent the first rigid foam panel, such that the first rigid foam panel is between the second rigid foam panel and the sheathing, and wherein the spray-pour foam is between the second rigid foam panel and the studs.

3. The insulated panel of claim 1, wherein the first rigid foam panel has beveled sides, the spray-pour foam between the beveled sides and the studs.

4. The insulated panel of claim 1, wherein the first rigid foam panel is made of expanded polystyrene.

5. The insulated panel of claim 2, wherein the second rigid foam panel is made of polyurethane.

6. The insulated panel of claim 1, wherein the spray-pour foam is a spray-pour polyurethane foam.

7. The insulated panel of claim 1, wherein the spray-pour foam includes pieces of pre-cured foam.

8. A method for fabricating an insulated foam panel comprising the steps of:

(a) inserting a first rigid foam panel against sheathing between studs;

(b) placing uncured foam adjacent the first rigid foam panel and between the studs.

9. The method of claim 8, further including the step of placing a second rigid foam panel against the first rigid foam panel, such that the first rigid foam panel is between the second rigid foam panel and the sheathing.

10. The method of claim 9 further including the step of placing uncured foam between the second rigid foam panel and the studs.

11. The method of claim 10, wherein the first rigid foam panel is expanded polystyrene.

12. The method of claim 11, wherein the second rigid foam panel is polyurethane.

13. The method of claim 8, wherein the first rigid foam panel has beveled sides, and wherein said step (b) includes the step of placing the uncured foam between the beveled sides and the studs.

14. The method of claim 8, wherein the uncured foam is a spray-pour polyurethane foam.

15. The method of claim 8, wherein the uncured foam includes pieces of pre-cured foam.