Methods and systems for insulating a building

• US 8,495,852 B2
• Filed: 11/01/2011
• Issued: 07/30/2013
• 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): Gilbert, William
• Assistant Examiner(s): FERENCE, JAMES M
• Application Number:
  US13/286,569
• Publication Number:
  US 20130104469A1
• Time in Patent Office: 637 Days
• Field of Search: 524/80, 524/043, 527/421.3, 527/450.9, 527/941, 524/041, 527/451.3
• US Class Current: 52/745.13
• 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 method of insulating a component of a building comprising:

providing a component of a building, the component comprising;

a generally planar surface; and

a frame comprising a plurality of outer components coupled together to define an outer periphery and one or more inner components that divide the frame into one or more sections, the frame being positioned atop one side of the generally planar surface so that at least one of the sections comprises a cavity;

applying a pour insulation material within the cavity to insulate the component, the pour insulation material being applied within the cavity such that when expanded, a top surface of the pour insulation material is substantially equal with a top surface of the cavity, wherein the pour insulation material transitions from a liquid state to a solid state to form a first layer of insulation within the cavity, and wherein the first layer of insulation comprises an insulation R value of between about R-3.5 and about R-7 per inch of the insulation; and

applying a second layer of loose fiber insulation atop the first layer of insulation.

2. The method of claim 1, wherein applying the pour insulation material comprises:

positioning a nozzle over the cavity; and

injecting the pour insulation material within the cavity through the nozzle.

3. The method of claim 2, further comprising:

positioning an additional nozzle over an additional cavity; and

injecting pour insulation material within the additional cavity simultaneously with the pour insulation material being injected within the cavity.

4. The method of claim 1, wherein:

the generally planar surface comprises a plurality of panels;

adjacent panels abut each other at a seam; and

the method further comprises sealing the seams prior to applying the pour insulation material.

5. The method of claim 4, wherein sealing the seams comprises applying a tape atop the seams.

6. The method of claim 1, wherein the first layer of insulation is applied at a site where the component is manufactured and the second layer of insulation is applied at a site where the component is installed to construct the building.

7. The method of claim 1, further comprising applying the second layer of insulation to a layer thickness of between about 1.5 inches and about 9 inches.

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

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

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

11. The method of claim 1, further comprising applying the pour insulation material within the cavity prior to the frame being adhesively coupled with the generally planar surface, wherein the pour insulation material adhesively couples the frame with the generally planar surface.

12. The method of claim 1, wherein the component comprises a roof or attic having one or more truss members positioned atop the generally planar surface, and wherein the method further comprises:

applying the pour insulation material within the cavity while the one or more truss members are positioned atop the generally planar surface.

13. The method 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 resulting first layer of insulation has a substantially equivalent layer thickness within the cavity.