Insulated panel

• US 9,260,865 B2
• Filed: 09/14/2012
• Issued: 02/16/2016
• 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): Herring, Brent W
• Application Number:
  US13/617,164
• Publication Number:
  US 20130008110A1
• Time in Patent Office: 1,250 Days
• Field of Search: 523/094, 523/095, 523/44, 523/49, 523/54, 524/041, 524/073, 524/08, 523/098, 527/941, 428/71, 428/306.6, 428/316.6, 264/46.5, 156/71, 156/78, 156/79, 156/293
• US Class Current: 1/1
• 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 secured by adhesive to the sheathing between the studs;

a spray-pour foam cured in place adjacent the first rigid foam panel and between the studs, wherein the spray-pour foam is distinct from the adhesive such that the spray-pour foam is not between the first rigid foam panel and the sheathing; and

a second rigid foam panel 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.

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

3. The insulated panel of claim 2, wherein the spray-pour foam is a spray-pour polyurethane foam.

4. The insulated panel of claim 3, wherein the spray-pour foam includes pieces of pre-cured foam.

5. The insulated panel of claim 3, 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.

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

7. The insulated panel of claim 5 wherein the second rigid foam panel is secured directly to the first rigid foam panel.

8. The insulated panel of claim 7 wherein the second rigid foam panel is secured to the first rigid foam panel by adhesive.

9. 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.

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

11. The insulated panel of claim 1, wherein the second rigid foam panel is made of polyurethane.

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

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

14. An insulated panel comprising:

a pair of spaced apart studs;

sheathing secured to the studs;

a first rigid foam panel secured by adhesive to the sheathing between the studs but the adhesive does not secure the first rigid foam panel to the studs;

a second rigid foam panel adjacent the first rigid foam panel, such that the first rigid foam panel is between the second rigid foam panel and the sheathing, wherein the first rigid foam panel and the second rigid foam panel are spaced away from the studs; and

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

15. The insulated panel of claim 14 wherein the spray-pour foam is cured in place against outer surfaces of the first rigid panel facing the studs.

16. An insulated panel comprising:

a pair of spaced apart studs;

sheathing secured to the studs;

a first rigid foam panel secured by adhesive to the sheathing between the studs, but the first rigid foam panel is not secured directly to the studs by the adhesive;

a second rigid foam panel adjacent the first rigid foam panel, such that the first rigid foam panel is between the second rigid foam panel and the sheathing, wherein the first rigid foam panel and the second rigid foam panel are spaced away from the studs; and

a spray-pour foam cured in place in the space between the first rigid foam panel and the studs and in the space between the second rigid foam panel and the studs wherein the spray-pour foam is not between the first rigid foam panel and the sheathing.