Insulated panel

• US 8,365,497 B2
• Filed: 08/19/2009
• Issued: 02/05/2013
• Est. Priority Date: 08/19/2008
• Status: Active Grant

• Current Assignee: Jordan Byron Rothwell
• Original Assignee: Jordan Byron Rothwell
• Inventors: Rothwell, Jordan Byron
• Primary Examiner(s): Canfield, Robert
• Assistant Examiner(s): Herring, Brent W
• Application Number:
  US12/543,747
• Publication Number:
  US 20100043327A1
• Time in Patent Office: 1,266 Days
• Field of Search: 523/094, 523/095, 523/44, 523/49, 523/54, 524/041, 524/073, 524/08, 527/421, 527/421.2, 527/421.3, 527/450.5, 523/098, 527/941, 527/421.1, 428/71, 428/306.6, 428/316.6, 264/46.5, 156/71, 156/78, 156/79, 156/293
• US Class Current: 52/742.12
• 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. 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 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;

(c) after said step (a), placing uncured foam between the first rigid foam panel and the studs and between the second rigid foam panel and the studs.

2. The method of claim 1, wherein the first rigid foam panel is expanded polystyrene.

3. The method of claim 2, wherein the second rigid foam panel is polyurethane.

4. The method of claim 3, wherein the uncured foam is a spray-pour polyurethane foam.

5. The method of claim 4, wherein the uncured foam includes pieces of pre-cured foam.

6. The method of claim 5, further including the steps of:

(d) placing spacers between the first rigid foam panel and the studs;

(e) securing the first rigid foam panel to the sheathing after said step (d) and after said step (a).

7. The method of claim 6 further including the step of removing the spacers before said step (c).