Methods and systems for insulating a building

• US 8,950,142 B2
• Filed: 06/21/2013
• Issued: 02/10/2015
• Est. Priority Date: 11/01/2011
• Status: Active Grant

• Current Assignee: Johns Manville Corporation (Berkshire Hathaway Incorporated)
• Original Assignee: Johns Manville Corporation (Berkshire Hathaway Incorporated)
• Inventors: Fay, Ralph Michael
• Primary Examiner(s): FERENCE, JAMES M
• Application Number:
  US13/923,552
• Publication Number:
  US 20130280467A1
• Time in Patent Office: 599 Days
• Field of Search: 524/80, 524/041, 524/043, 527/421.3, 527/450.9, 527/941, 527/451.3, 524/044, 524/071, 524/072, 524/073, 524/075
• US Class Current: 52/404.3
• CPC Class Codes: B29C 44/386 using a movable, elongate nozzle, e.g. to reach deep into the mould
• CPC Class Codes: E04B 1/62 Insulation or other protection; Elements or use of specified material therefor chemical compositions C01 - C11; implements for applying insulation or sealings E04F21/00; buildings to withstand, or to provide protection against, external undesired influences E04H9/00; sealing pipes in walls or partitions F16L5/02; shielding against dangerous radiation G21F
• CPC Class Codes: E04B 1/74 Heat, sound or noise insulation, absorption, or reflection forms of, or arrangements in, rooms for influencing or directing sound E04B1/99; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls fire protection E04B1/94; elements chiefly adapted for structural purposes E04C1/00 - E04C3/00; chiefly adapted for surface coverings E04F13/00; as underlayers for floor coverings E04F15/18; closures for wall or like openings E06B
• CPC Class Codes: E04B 1/7604 fillings for cavity walls
• CPC Class Codes: E04D 13/1631 the means deriving from the nature or the shape of the insulating material itself
• CPC Class Codes: E04D 13/1675 on saddle-roofs or inclined roof surfaces
• CPC Class Codes: Y02A 30/00 Adapting or protecting infrastructure or their operation
• CPC Class Codes: Y02B 30/90 Passive houses; Double facade technology
• CPC Class Codes: Y10T 428/23 Sheet including cover or casing

Abstract

Embodiments of the invention provide systems and methods for insulating a component of a home or building. An insulated component may include a generally planar surface and a frame positioned atop one side of the generally planar surface. The frame may include a plurality of outer studs coupled together to form an outer periphery and inner studs that divide the frame into one or more sections. One or more of the sections may include a cavity or hollow space. The insulated component may also include a first layer of insulation within one or more of the cavities. The first layer of insulation may include a pour insulation material that transitions from a liquid state or phase to a solid state or phase.

Claims

1. A component of a structure comprising:

a generally planar surface;

a frame comprising;

a plurality of outer studs coupled together to define an outer periphery,

each of said outer studs having a width between a bottom surface of each of said outer studs and a top surface of each of said outer studs; and

one or more inner studs that divide the frame into one or more sections, each of said one or more inner studs having a width between a bottom surface of each of said one or more inner studs and a top surface of each of said one or more inner studs, wherein the frame is positioned atop one side of the generally planar surface so that at least one of the sections comprises a cavity, the frame having a substantially coplanar bottom surface that contacts the generally planar surface and a substantially coplanar top surface positioned opposite the bottom surface of the frame, wherein the width of each of said outer studs and each of said one or more inner studs is substantially the same so that the bottom surface of each of said outer studs and each of said one or more inner studs is substantially coplanar with the bottom surface of the frame and the top surface of each of said outer studs and each of said one or more inner studs is substantially coplanar with the top surface of the frame;

a first layer of pour insulation material within the cavity, the first layer of insulation having a substantially equivalent layer thickness throughout the cavity and having an insulation R value of between about R-4 and about R-7 per inch of the insulation, wherein the pour insulation material transitions from a liquid state to a solid state and expands during the transition, and wherein the pour insulation material is applied within the cavity such that when expanded, a top surface of the pour insulation material is substantially adjacent the top surface of the frame; and

a second layer of insulation positioned atop the first layer of insulation so as to extend above the top surface of the frame, the second layer of insulation comprising loose fill fiber insulation.

2. The component of claim 1, wherein the component comprises an attic.

3. The component of claim 1, wherein the structure comprises an attic or roof of a manufactured or modular home.

4. The component of claim 3, wherein the attic or roof comprises a maximum height of between about 1 foot and about 4 feet.

5. The component of claim 1, wherein the insulation R value of a combination of the first and second layers of insulation is between about R-40 and about R-60.

6. The component of claim 1, wherein the layer thickness of the first layer of insulation is between about 2 inches and about 5 inches.

7. The component of claim 1, wherein the generally planar surface comprises a plurality of panels, wherein adjacent panels of said plurality of panels abut each other at seams, and wherein each of said seams is sealed with a tape material.

8. The component of claim 1, wherein the pour insulation material adhesively couples the frame with the generally planar surface.

9. The component of claim 1, wherein the pour insulation material comprises a closed cell foam.

10. The component of claim 1, wherein the pour insulation material comprises an open cell foam.

11. The component of claim 1, wherein the component further comprises one or more truss members positioned atop the generally planar surface.

12. The component of claim 1, wherein the pour insulation material comprises a low viscosity and slow cream time that allows the pour insulation material to spread out within the cavity in the liquid state so that the first layer of insulation has a substantially equivalent layer thickness within the cavity.