US20070074474A1 - Insulating wall assembly, and structure including the same - Google Patents
Insulating wall assembly, and structure including the same Download PDFInfo
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- US20070074474A1 US20070074474A1 US11/544,585 US54458506A US2007074474A1 US 20070074474 A1 US20070074474 A1 US 20070074474A1 US 54458506 A US54458506 A US 54458506A US 2007074474 A1 US2007074474 A1 US 2007074474A1
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- United States
- Prior art keywords
- wall assembly
- framework
- studs
- foam
- vertical support
- Prior art date
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- Abandoned
Links
- 239000006260 foam Substances 0.000 claims abstract description 26
- 229920002635 polyurethane Polymers 0.000 claims abstract description 21
- 239000004814 polyurethane Substances 0.000 claims abstract description 21
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 19
- 229910052602 gypsum Inorganic materials 0.000 claims description 13
- 239000010440 gypsum Substances 0.000 claims description 13
- 229920000582 polyisocyanurate Polymers 0.000 claims description 9
- 239000011495 polyisocyanurate Substances 0.000 claims description 9
- 239000004698 Polyethylene Substances 0.000 claims description 8
- -1 polyethylene Polymers 0.000 claims description 8
- 229920000573 polyethylene Polymers 0.000 claims description 8
- 239000011888 foil Substances 0.000 claims description 6
- 229920005830 Polyurethane Foam Polymers 0.000 claims description 5
- 239000011496 polyurethane foam Substances 0.000 claims description 5
- 230000000712 assembly Effects 0.000 description 6
- 238000000429 assembly Methods 0.000 description 6
- 238000009413 insulation Methods 0.000 description 6
- 210000002268 wool Anatomy 0.000 description 5
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 4
- 238000010276 construction Methods 0.000 description 4
- 230000014509 gene expression Effects 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 238000000034 method Methods 0.000 description 4
- 230000006872 improvement Effects 0.000 description 2
- 239000002984 plastic foam Substances 0.000 description 2
- 230000004888 barrier function Effects 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
- 238000004078 waterproofing Methods 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/7604—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only fillings for cavity walls
Definitions
- the present invention relates to an improved wall assembly. More particularly, and in its preferred embodiment, the present invention relates to an insulating wall assembly, similarly to walls pre-manufactured in factories for the construction of residential, commercial or industrial buildings, such as, for example, apartment buildings, garages, family homes, etc.
- the present invention also relates to a structure, such as a building for example, comprising at least one such wall assembly.
- standard walls are generally fabricated with insulating wool inside the walls.
- the wool is generally not as efficient as one would hope for, particularly in very harsh conditions, such as North American winters.
- standard wool laid within the walls of 40 feet in length reduces its degree of insulation, the latter passing from R20 to R11.
- An object of the present invention is to provide an insulating wall assembly, which by virtue of its design and components, satisfies some of the above-mentioned concerns and is thus an improvement over other related insulating wall assemblies and/or insulating methods known in the prior art.
- an insulating wall assembly comprising:
- a substantially rectangular framework having opposite interior and exterior sides, the framework comprising a plurality of vertical support studs mounted to a plurality of horizontal end studs so as to define at least one inner spacing within the framework, the vertical support studs and the horizontal end studs having each opposite front and rear sides corresponding to the interior and exterior sides of the framework;
- outer components mounted respectively onto the interior and exterior sides of the framework so as to close up the framework and provide the wall assembly with additional insulating capabilities.
- the outer components comprise a polyethylene cover mounted onto the front sides of the studs so as to entirely cover the interior side of the framework.
- the outer components comprises a plurality of plates each being mounted respectively onto a front side of a corresponding vertical support stud, and a gypsum panel operatively mounted onto the front sides of the vertical support studs via the plates, an air space being defined between the polyethylene cover and the gypsum panel, said air space providing the wall assembly with additional insulating capabilities.
- the outer components comprise a polyisocyanurate panel operatively mounted onto the rear sides of the studs so as to entirely cover the exterior side of the framework.
- the plates are provided with AP foil bands.
- each inner spacing comprises a traversal dividing stud connected between a pair of adjacent vertical support studs so as to divide said inner spacing into upper and lower inner spacings, said upper and lower inner spacings being completely filled with the foam of water-based polyurethane.
- the foam of water-based polyurethane is a foam with open cells, and more particularly, the foam of water-based polyurethane is preferably a semi-rigid 1 ⁇ 2 pound density pour-in-place polyurethane foam, commercialized under B500TM by DÉMILEC.
- the vertical support studs and the horizontal end studs are 2′′ ⁇ 6′′ studs
- the plates are 1′′ ⁇ 2′′ plates
- adjacent vertical support studs are spaced apart from one another by a transversal distance of about 16′′
- the thickness of the gypsum panel is about 1 ⁇ 2′′
- the thickness of the polyisocyanurate panel is about 1 ⁇ 2′′.
- the overall R value of the insulating wall assembly is about R30.
- a structure comprising at least one of the above-mentioned insulating wall assembly, and preferably, a plurality of such insulating wall assemblies.
- FIG. 1 represents a partial schematic view of an interior side wall assembly according to a preferred embodiment of the present invention.
- FIG. 2 represents a partial schematic view of an exterior side wall assembly according to another preferred embodiment of the present invention.
- FIG. 3 is a sectional view of a wall assembly according to yet another preferred embodiment of the present invention.
- the present invention was primarily designed for insulating purposes, and particularly for heat insulation purposes, it may be used with other types of objects, for other purposes and in other fields, such as for soundproofing, for example, as apparent to a person skilled in the art.
- expressions such as “insulating”, “wall”, “assembly”, “home”, “residential”, “building”, etc. as used herein should not be taken as to limit the scope of the present invention and includes all other kind of items and/or purposes with which the present invention could be used and may be useful.
- the insulating wall assembly 1 is an improved insulating wall assembly 1 comprising different components, materials, and/or features, interrelated with one another, and destined to be used, preferably, in walls pre-manufactured in factories for the subsequent construction of residential, commercial or industrial buildings, on site, such as, for example, apartment buildings, garages, family homes, etc., as apparent to a person skilled in the art in view of the present description.
- the insulating wall assembly 1 comprises a substantially rectangular framework 3 having opposite interior and exterior sides 3 a , 3 b , the framework 3 comprising a plurality of vertical support studs 5 mounted to a plurality of horizontal end studs 7 so as to define at least one inner spacing 9 within the framework 3 , the vertical support studs 5 and the horizontal end studs 7 having each opposite front and rear sides 5 a , 7 a , 5 b , 7 b corresponding to the interior and exterior sides 3 a , 3 b of the framework 3 .
- a foam 11 of water-based polyurethane is injected into said at least one inner spacing 9 so as to complete fill the same and provide the wall assembly 1 with insulating capabilities.
- the wall assembly 1 also comprises outer components 13 mounted respectively onto the interior and exterior sides 3 a , 3 b of the framework 3 so as to close up the framework 3 and provide the wall assembly 1 with additional insulating capabilities.
- the outer components 13 comprise a polyethylene cover 15 mounted onto the front sides 5 a , 7 a of the studs 5 , 7 so as to entirely cover the interior side 3 a of the framework 3 , as better shown in FIG. 3 .
- the outer components 13 comprises a plurality of plates 17 each being mounted respectively onto a front side 5 a of a corresponding vertical support stud 5 , and a gypsum panel 19 operatively mounted onto the front sides 5 a of the vertical support studs 5 via the plates 17 , an air space 21 being defined between the polyethylene cover 15 and the gypsum panel 19 , said air space 21 providing the wall assembly 1 with additional insulating capabilities.
- the outer components 13 comprise a polyisocyanurate panel 23 operatively mounted onto the rear sides 5 b , 7 b of the studs 5 , 7 so as to entirely cover the exterior side 3 b of the framework 3 .
- the plates 17 are provided with AP foil bands.
- each inner spacing 9 comprises a traversal dividing stud 25 connected between a pair of adjacent vertical support studs 5 so as to divide said inner spacing 9 into upper and lower inner spacings 9 , said upper and lower inner spacings 9 being completely filled with the foam 11 of water-based polyurethane.
- the foam 11 of water-based polyurethane is a foam 11 with open cells, and more particularly, the foam 11 of water-based polyurethane is preferably a semi-rigid 1 ⁇ 2 pound density pour-in-place polyurethane foam 11 , commercialized under B500TM by DÉMILEC.
- the vertical support studs 5 and the horizontal end studs 7 are 2′′ ⁇ 6′′ studs
- the plates 17 are 1′′ ⁇ 2′′ plates
- adjacent vertical support studs 5 are spaced apart from one another by a transversal distance d of about 16′′
- the thickness of the gypsum panel 19 is about 1 ⁇ 2′′
- the thickness of the polyisocyanurate panel 23 is about 1 ⁇ 2′′.
- the overall R′ value of the insulating wall assembly 1 is about R30.
- the present invention could be used in the manufacturing of structures comprising pre-fabricated construction components, such as wall panels, floor beams and assembled floors, as well as roof truss structures, and the like, as apparent to a person skilled in the art.
- the proposed product is preferably a wall assembly 1 having been insulated with urethane.
- a semi-rigid 1 ⁇ 2 pound density foam of polyurethane B500TM pored in place (PIP) which is preferably injected inside the wall, and this, preferably, in the manufacturing or assembling plant, before putting out to construction.
- the insulating wall assembly 1 preferably provides several advantages when compared to conventional walls, examples of which are the following: a) ecological (Eco-Logo); b) Energy Star; c) compliant with NOVO-CLIMAT norms; d) improved noise reduction; e) rate of flame propagation no higher than a conventional wall—preferably, this rate of propagation of flame corresponds to the class #1 of American norms; and f) overall insulation of about R30.
- the use of a plastic foam 11 according to the present invention is advantageous in the measure where it always keeps the same R value irrespectively of the length of the wall, this R value being preferably R20, approximately.
- the urethane or the plastic foam 11 is considered an important feature of the present system.
- the above-mentioned “Ap foil” bands and panels may be considered optional, but are also considered to be more advantageous whenever present from an insulation point of view.
- the present invention is advantageous in that the urethane comprises increased sound proofing capabilities with respect to insulating wool. Furthermore, it is more ecological and enables for a superior water proofing with respect to a conventional walls filled with insulating wool. Furthermore, by incorporating the “Ap foil” bands (urethane panels) in front of the studs 5 , 7 , as better illustrated in the accompanying drawings, this enables to prevent a thermal bridge between the exterior and the interior of the wall assembly 1 .
- the wall assembly 1 is manufactured in factory using a semi-rigid 1 ⁇ 2 pound density foam of polyurethane B500TM PIP, preferably also with 2′′ ⁇ 5′′ studs with a 1′′ polyisocyanurate panel on the inside portion of the wall, as better illustrated in FIG. 1 , and preferably also, with polyisocyanurate panel on the outside portion of the wall, as better illustrated in FIG. 2 .
- the present invention is a substantial improvement over the prior art, in that, by virtue of its design and components, the insulating wall assembly 1 is simple and easy to use, as well as simple and easy to manufacture and/or assemble, without compromising the reliability of its components and features.
- the present invention represents important advantages over other related insulating walls known in the prior art, namely in terms of ease of manufacturing or assembling and improved insulation, as well as being more environmentally friendly, as briefly explained hereinabove.
Abstract
An insulating wall assembly including a substantially rectangular framework having opposite interior and exterior sides, the framework including a plurality of vertical support studs mounted to a plurality of horizontal end studs so as to define at least one inner spacing within the framework, the vertical support studs and the horizontal end studs having each opposite front and rear sides corresponding to the interior and exterior sides of the framework. A foam of water-based polyurethane is injected into said at least one inner spacing so as to complete fill the same and provide the wall assembly with insulating capabilities. Outer components are mounted respectively onto the interior and exterior sides of the framework so as to close up the framework and provide the wall assembly with additional insulating capabilities.
Description
- The present invention relates to an improved wall assembly. More particularly, and in its preferred embodiment, the present invention relates to an insulating wall assembly, similarly to walls pre-manufactured in factories for the construction of residential, commercial or industrial buildings, such as, for example, apartment buildings, garages, family homes, etc. The present invention also relates to a structure, such as a building for example, comprising at least one such wall assembly. The present application claims priority of Canadian patent application No. 2,522,887 dated Oct. 7, 2005, the content of which is incorporated herein by reference.
- Known to the Applicant are the following U.S. patents and patent applications which describe different wall structures, assemblies and the like: U.S. Pat. Nos. 3,029,501; 3,797,190; 3,885,008; 3,965,635; 4,572,861; 4,694,624; 4,856,244; 4,914,883; 5,765,330; 5,861,119; 6,099,768; 6,247,280 B1; 6,330,775 B1; 6,332,304 B1; 2003/0150183 A1; and 2004/0216401 A1.
- Also known to the Applicant is the following Japanese document, namely, JP No. 2004-308297.
- It is also well known in the art that standard walls are generally fabricated with insulating wool inside the walls. The wool is generally not as efficient as one would hope for, particularly in very harsh conditions, such as North American winters. For example, standard wool laid within the walls of 40 feet in length reduces its degree of insulation, the latter passing from R20 to R11.
- Furthermore, it is known in the art that it is very important for consumers nowadays to have a home as energy sound as possible, while ensuring a respect for the environment that takes on a greater importance in society, that is why the different walls used in the industry also need to meet these different criteria.
- In view of the above, and for various different other reasons, there is a need for an improved insulating wall assembly, which by virtue of its design and components, would be able to overcome some of the concerns known in the prior art.
- An object of the present invention is to provide an insulating wall assembly, which by virtue of its design and components, satisfies some of the above-mentioned concerns and is thus an improvement over other related insulating wall assemblies and/or insulating methods known in the prior art.
- In accordance with the present invention, the above object is achieved, as will be easily understood, with an insulating wall assembly, such as the one briefly described herein, and such as the one exemplified in the accompanying drawings.
- More particularly, according to the present invention, there is provided an insulating wall assembly comprising:
- a substantially rectangular framework having opposite interior and exterior sides, the framework comprising a plurality of vertical support studs mounted to a plurality of horizontal end studs so as to define at least one inner spacing within the framework, the vertical support studs and the horizontal end studs having each opposite front and rear sides corresponding to the interior and exterior sides of the framework;
- a foam of water-based polyurethane injected into said at least one inner spacing so as to complete fill the same and provide the wall assembly with insulating capabilities; and
- outer components mounted respectively onto the interior and exterior sides of the framework so as to close up the framework and provide the wall assembly with additional insulating capabilities.
- Preferably, the outer components comprise a polyethylene cover mounted onto the front sides of the studs so as to entirely cover the interior side of the framework.
- Preferably also, the outer components comprises a plurality of plates each being mounted respectively onto a front side of a corresponding vertical support stud, and a gypsum panel operatively mounted onto the front sides of the vertical support studs via the plates, an air space being defined between the polyethylene cover and the gypsum panel, said air space providing the wall assembly with additional insulating capabilities.
- Preferably also, the outer components comprise a polyisocyanurate panel operatively mounted onto the rear sides of the studs so as to entirely cover the exterior side of the framework.
- Preferably also, the plates are provided with AP foil bands.
- Preferably also, each inner spacing comprises a traversal dividing stud connected between a pair of adjacent vertical support studs so as to divide said inner spacing into upper and lower inner spacings, said upper and lower inner spacings being completely filled with the foam of water-based polyurethane.
- Preferably also, the foam of water-based polyurethane is a foam with open cells, and more particularly, the foam of water-based polyurethane is preferably a semi-rigid ½ pound density pour-in-place polyurethane foam, commercialized under B500™ by DÉMILEC.
- Preferably also, the vertical support studs and the horizontal end studs are 2″×6″ studs, the plates are 1″×2″ plates, adjacent vertical support studs are spaced apart from one another by a transversal distance of about 16″, the thickness of the gypsum panel is about ½″, and the thickness of the polyisocyanurate panel is about ½″.
- Preferably also, the overall R value of the insulating wall assembly is about R30.
- According to yet another aspect of the present invention, there is also provided a structure comprising at least one of the above-mentioned insulating wall assembly, and preferably, a plurality of such insulating wall assemblies.
- According to yet another aspect of the present invention, there is also provided a method of assembling the above-mentioned wall assemblies and/or structure.
- According to yet another aspect of the present invention, there is also provided a method of mounting the above-mentioned insulating wall assemblies and/or structure.
- According to yet another aspect of the present invention, there is also provided a kit for assembling the above-mentioned insulating wall assemblies and/or structure.
- According to yet another aspect of the present invention, there is also provided a method for assembling components of the above-mentioned kit.
- The objects, advantages and other features of the present invention will become more apparent upon reading of the following non-restrictive description of preferred embodiments thereof, given for the purpose of exemplification only, with reference to the accompanying drawings.
-
FIG. 1 represents a partial schematic view of an interior side wall assembly according to a preferred embodiment of the present invention. -
FIG. 2 represents a partial schematic view of an exterior side wall assembly according to another preferred embodiment of the present invention. -
FIG. 3 is a sectional view of a wall assembly according to yet another preferred embodiment of the present invention. - In the following description, the same numerical references refer to similar elements. The embodiments shown in the figures are preferred and are namely used for exemplification purposes only.
- Moreover, although the present invention was primarily designed for insulating purposes, and particularly for heat insulation purposes, it may be used with other types of objects, for other purposes and in other fields, such as for soundproofing, for example, as apparent to a person skilled in the art. For this reason, expressions such as “insulating”, “wall”, “assembly”, “home”, “residential”, “building”, etc. as used herein should not be taken as to limit the scope of the present invention and includes all other kind of items and/or purposes with which the present invention could be used and may be useful.
- Moreover, in the context of the present invention, the expressions “wall”, “structure”, “assembly”, and any other equivalent expressions known in the art will be used interchangeably. Furthermore, the same applies for any other mutually equivalent expressions, such as “vertical” and “horizontal”, as well as “studs” and “plates” for example, as also apparent to a person skilled in the art.
- In addition, although the preferred embodiment of the present invention as illustrated in the accompanying drawings comprises various components and although the preferred embodiment of the insulating wall assembly 1 as shown consists of certain geometrical configurations as briefly explained and illustrated herein, not all of these components and geometries are essential to the invention and thus should not be taken in their restrictive sense, i.e. should not be taken as to limit the scope of the present invention. It is to be understood, as also apparent to a person skilled in the art, that other suitable components and cooperations thereinbetween, as well as other suitable geometrical configurations may be used for the insulating wall assembly 1 and corresponding parts according to the present invention, as briefly explained and as can be easily inferred herefrom by a person skilled in the art, without departing from the scope of the present invention.
- Broadly described, the insulating wall assembly 1 according to the present invention, as shown in the accompanying drawings, is an improved insulating wall assembly 1 comprising different components, materials, and/or features, interrelated with one another, and destined to be used, preferably, in walls pre-manufactured in factories for the subsequent construction of residential, commercial or industrial buildings, on site, such as, for example, apartment buildings, garages, family homes, etc., as apparent to a person skilled in the art in view of the present description.
- As better exemplified in the accompanying drawings, the insulating wall assembly 1 according to the present invention comprises a substantially
rectangular framework 3 having opposite interior andexterior sides framework 3 comprising a plurality ofvertical support studs 5 mounted to a plurality ofhorizontal end studs 7 so as to define at least oneinner spacing 9 within theframework 3, thevertical support studs 5 and thehorizontal end studs 7 having each opposite front andrear sides exterior sides framework 3. - Also according to the present invention, a
foam 11 of water-based polyurethane is injected into said at least oneinner spacing 9 so as to complete fill the same and provide the wall assembly 1 with insulating capabilities. - The wall assembly 1 also comprises
outer components 13 mounted respectively onto the interior andexterior sides framework 3 so as to close up theframework 3 and provide the wall assembly 1 with additional insulating capabilities. - Preferably, the
outer components 13 comprise apolyethylene cover 15 mounted onto the front sides 5 a,7 a of thestuds interior side 3 a of theframework 3, as better shown inFIG. 3 . - Preferably also, the
outer components 13 comprises a plurality ofplates 17 each being mounted respectively onto a front side 5 a of a correspondingvertical support stud 5, and agypsum panel 19 operatively mounted onto the front sides 5 a of thevertical support studs 5 via theplates 17, anair space 21 being defined between thepolyethylene cover 15 and thegypsum panel 19, saidair space 21 providing the wall assembly 1 with additional insulating capabilities. - Preferably also, the
outer components 13 comprise apolyisocyanurate panel 23 operatively mounted onto therear sides studs exterior side 3 b of theframework 3. - Preferably also, the
plates 17 are provided with AP foil bands. - Preferably also, each
inner spacing 9 comprises a traversal dividing stud 25 connected between a pair of adjacentvertical support studs 5 so as to divide saidinner spacing 9 into upper and lowerinner spacings 9, said upper and lowerinner spacings 9 being completely filled with thefoam 11 of water-based polyurethane. - Preferably also, the
foam 11 of water-based polyurethane is afoam 11 with open cells, and more particularly, thefoam 11 of water-based polyurethane is preferably a semi-rigid ½ pound density pour-in-place polyurethane foam 11, commercialized under B500™ by DÉMILEC. - Preferably also, the
vertical support studs 5 and thehorizontal end studs 7 are 2″×6″ studs, theplates 17 are 1″×2″ plates, adjacentvertical support studs 5 are spaced apart from one another by a transversal distance d of about 16″, the thickness of thegypsum panel 19 is about ½″, and the thickness of thepolyisocyanurate panel 23 is about ½″. - Preferably also, the overall R′ value of the insulating wall assembly 1 is about R30.
- As may now be better appreciated, the present invention could be used in the manufacturing of structures comprising pre-fabricated construction components, such as wall panels, floor beams and assembled floors, as well as roof truss structures, and the like, as apparent to a person skilled in the art.
- According to a preferred embodiment of the present invention, the proposed product is preferably a wall assembly 1 having been insulated with urethane. As can be easily understood by a person skilled in the art in view of the accompanying figures, and according to the present invention, it is preferably carried out using a semi-rigid ½ pound density foam of polyurethane B500™ pored in place (PIP) which is preferably injected inside the wall, and this, preferably, in the manufacturing or assembling plant, before putting out to construction.
- The insulating wall assembly 1 according to the present invention preferably provides several advantages when compared to conventional walls, examples of which are the following: a) ecological (Eco-Logo); b) Energy Star; c) compliant with NOVO-CLIMAT norms; d) improved noise reduction; e) rate of flame propagation no higher than a conventional wall—preferably, this rate of propagation of flame corresponds to the class #1 of American norms; and f) overall insulation of about R30.
- As can be also easily understood by a person skilled in the art in view of the accompanying drawings, and the present description, the preferred components and features of the wall assembly 1 according to the present invention are briefly summarized hereinbelow in table form:
PREFERRED COMPONENTS AND FEATURES OF THE WALL R Film of outer air 0.17 Vinyl dressing 0.61 ¾″ space of air 1.02 ¾″ coating — ½″ outer gypsum 0.42 Polyurethane foam 20.96 5½″ (2″ x 6″) stud — Vapour barrier — ½″ inner gypsum 0.42 Film of inner air 0.68 Ap panel (Johns Manville) 3.30 100% continuous insulation of inside — - As may now be better appreciated by a person skilled in the art in view of the present description, table and accompanying figures, the use of a
plastic foam 11 according to the present invention is advantageous in the measure where it always keeps the same R value irrespectively of the length of the wall, this R value being preferably R20, approximately. - In the same order of ideas, the urethane or the
plastic foam 11 is considered an important feature of the present system. Furthermore, the above-mentioned “Ap foil” bands and panels may be considered optional, but are also considered to be more advantageous whenever present from an insulation point of view. - In view of the above described, one may notice also that the present invention is advantageous in that the urethane comprises increased sound proofing capabilities with respect to insulating wool. Furthermore, it is more ecological and enables for a superior water proofing with respect to a conventional walls filled with insulating wool. Furthermore, by incorporating the “Ap foil” bands (urethane panels) in front of the
studs - Moreover, as can be easily understood by a person skilled in the art in view of the accompanying drawings, and according to the present invention, the wall assembly 1 is manufactured in factory using a semi-rigid ½ pound density foam of polyurethane B500™ PIP, preferably also with 2″×5″ studs with a 1″ polyisocyanurate panel on the inside portion of the wall, as better illustrated in
FIG. 1 , and preferably also, with polyisocyanurate panel on the outside portion of the wall, as better illustrated inFIG. 2 . - As may now be better appreciated by a person skilled in the art, the present invention is a substantial improvement over the prior art, in that, by virtue of its design and components, the insulating wall assembly 1 is simple and easy to use, as well as simple and easy to manufacture and/or assemble, without compromising the reliability of its components and features. Hence, it may now be better appreciated that the present invention represents important advantages over other related insulating walls known in the prior art, namely in terms of ease of manufacturing or assembling and improved insulation, as well as being more environmentally friendly, as briefly explained hereinabove.
- Of course, numerous modifications could be made to the above-described embodiments without departing from the scope of the present invention, as defined in the appended claims.
Claims (20)
1. An insulating wall assembly comprising:
a substantially rectangular framework having opposite interior and exterior sides, the framework comprising a plurality of vertical support studs mounted to a plurality of horizontal end studs so as to define at least one inner spacing within the framework, the vertical support studs and the horizontal end studs having each opposite front and rear sides corresponding to the interior and exterior sides of the framework;
a foam of water-based polyurethane injected into said at least one inner spacing so as to complete fill the same and provide the wall assembly with insulating capabilities; and
outer components mounted respectively onto the interior and exterior sides of the framework so as to close up the framework and provide the wall assembly with additional insulating capabilities.
2. An insulating wall assembly according to claim 1 , wherein the outer components comprise a polyethylene cover mounted onto the front sides of the studs so as to entirely cover the interior side of the framework.
3. An insulating wall assembly according to claim 2 , wherein the outer components comprises a plurality of plates each being mounted respectively onto a front side of a corresponding vertical support stud, and a gypsum panel operatively mounted onto the front sides of the vertical support studs via the plates, an air space being defined between the polyethylene cover and the gypsum panel, said air space providing the wall assembly with additional insulating capabilities.
4. An insulating wall assembly according to claim 3 , wherein the outer components comprise a polyisocyanurate panel operatively mounted onto the rear sides of the studs so as to entirely cover the exterior side of the framework.
5. An insulating wall assembly according to claim 4 , wherein the plates are provided with AP foil bands.
6. An insulating wall assembly according to claim 5 , wherein each inner spacing comprises a traversal dividing stud connected between a pair of adjacent vertical support studs so as to divide said inner spacing into upper and lower inner spacings, said upper and lower inner spacings being completely filled with the foam of water-based polyurethane.
7. An insulating wall assembly according to claim 6 , wherein the foam of water-based polyurethane is a foam with open cells.
8. An insulating wall assembly according to claim 7 , wherein the foam of water-based polyurethane is a semi-rigid ½ pound density pour-in-place polyurethane foam.
9. An insulating wall assembly according to claim 8 , wherein the foam of water-based polyurethane is B500™ foam.
10. An insulating wall assembly according to claim 9 , wherein the vertical support studs and the horizontal end studs are 2″×6″ studs, the plates are 1″×2″ plates, adjacent vertical support studs are spaced apart from one another by about 16″, the thickness of the gypsum panel is about ½″, and the thickness of the polyisocyanurate panel is about ½″.
11. An insulating wall assembly according to claim 10 , wherein the overall R value of the insulating wall assembly is about R30.
12. A structure at least one insulating wall assembly, each insulating wall assembly comprising:
a substantially rectangular framework having opposite interior and exterior sides, the framework comprising a plurality of vertical support studs mounted to a plurality of horizontal end studs so as to define at least one inner spacing within the framework, the vertical support studs and the horizontal end studs having each opposite front and rear sides corresponding to the interior and exterior sides of the framework;
a foam of water-based polyurethane injected into said at least one inner spacing so as to complete fill the same and provide the wall assembly with insulating capabilities; and
outer components mounted respectively onto the interior and exterior sides of the framework so as to close up the framework and provide the wall assembly with additional insulating capabilities.
13. A structure according to claim 12 , wherein the outer components comprise a polyethylene cover mounted onto the front sides of the studs so as to entirely cover the interior side of the framework.
14. A structure according to claim 13 , wherein the outer components comprises a plurality of plates each being mounted respectively onto a front side of a corresponding vertical support stud, and a gypsum panel operatively mounted onto the front sides of the vertical support studs via the plates, an air space being defined between the polyethylene cover and the gypsum panel, said air space providing the wall assembly with additional insulating capabilities.
15. A structure according to claim 14 , wherein the outer components comprise a polyisocyanurate panel operatively mounted onto the rear sides of the studs so as to entirely cover the exterior side of the framework.
16. A structure according to claim 15 , wherein the plates are provided with AP foil bands.
17. A structure according to claim 16 , wherein each inner spacing comprises a traversal dividing stud connected between a pair of adjacent vertical support studs so as to divide said inner spacing into upper and lower inner spacings, said upper and lower inner spacings being completely filled with the foam of water-based polyurethane.
18. A structure according to claim 17 , wherein the foam of water-based polyurethane is a foam with open cells.
19. An insulating wall assembly according to claim 18 , wherein the foam of water-based polyurethane is a semi-rigid ½ pound density pour-in-place polyurethane foam, commercialized under B500™.
20. A kit for assembling an insulating wall assembly, comprising:
a substantially rectangular framework having opposite interior and exterior sides, the framework comprising a plurality of vertical support studs mountable to a plurality of horizontal end studs so as to define at least one inner spacing within the framework, the vertical support studs and the horizontal end studs having each opposite front and rear sides corresponding to the interior and exterior sides of the framework;
a foam of water-based polyurethane injectable into said at least one inner spacing so as to complete fill the same and provide the wall assembly with insulating capabilities; and
outer components mountable respectively onto the interior and exterior sides of the framework so as to close up the framework and provide the wall assembly with additional insulating capabilities.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA002522887A CA2522887A1 (en) | 2005-10-07 | 2005-10-07 | Insulating wall and structure comprising at least one such wall |
CA2,522,887 | 2005-10-07 |
Publications (1)
Publication Number | Publication Date |
---|---|
US20070074474A1 true US20070074474A1 (en) | 2007-04-05 |
Family
ID=37900620
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/544,585 Abandoned US20070074474A1 (en) | 2005-07-10 | 2006-10-10 | Insulating wall assembly, and structure including the same |
Country Status (2)
Country | Link |
---|---|
US (1) | US20070074474A1 (en) |
CA (2) | CA2522887A1 (en) |
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US20060265985A1 (en) * | 2005-05-25 | 2006-11-30 | Nichols Michael P | Insulated wall panel for building construction and method and apparatus for manufacture thereof |
US20100005746A1 (en) * | 2008-07-10 | 2010-01-14 | Dany Lemay | Insulating prefab wall structure |
US20110024432A1 (en) * | 2009-07-28 | 2011-02-03 | Jorgensen Roy W | Secondary containment system for DEF storage container |
CN102182297A (en) * | 2011-04-08 | 2011-09-14 | 杨洪春 | Hybrid outer wall heat insulation layer construction process |
US20110225911A1 (en) * | 2010-03-22 | 2011-09-22 | Battisti Peter L | Self-bailing interior frame |
US20120011792A1 (en) * | 2010-07-15 | 2012-01-19 | Dewildt Dean P | High strength light-framed wall structure |
US20120151869A1 (en) * | 2010-12-20 | 2012-06-21 | United States Gypsum Company | Insulated drywall ceiling on steel "c" joists |
US20130081346A1 (en) * | 2011-10-03 | 2013-04-04 | Ames Kulprathipanja | Methods and systems for sealing a wall |
US8621804B2 (en) | 2010-04-09 | 2014-01-07 | Materiaux Laurier Inc. | Insulating wall panel assembly and method for manufacturing same |
FR2994989A1 (en) * | 2012-09-03 | 2014-03-07 | Jerome Maignan | METHOD FOR CONSTRUCTING FACADE OF PREMISES INTENDED IN PARTICULAR FOR HABITATION AND ASSOCIATED FACADE OF PREMISES |
US20140090322A1 (en) * | 2012-03-13 | 2014-04-03 | Schabel Polymer Technology, Llc | Structural assembly insulation |
US8978342B2 (en) | 2012-06-15 | 2015-03-17 | Auburn University | Residential radiant barrier assemblies |
US20150093535A1 (en) * | 2013-09-27 | 2015-04-02 | Bayer Materialscience Llc | Foam wall structure |
US9834923B1 (en) * | 2015-08-10 | 2017-12-05 | Robert Lepage | Building construction method |
US10267030B1 (en) * | 2015-08-10 | 2019-04-23 | Robert Lepage | Building construction method |
US20220049493A1 (en) * | 2020-08-13 | 2022-02-17 | Certainteed Llc | Loose-Fill Insulated Building Structures and Methods for Making Them |
US20220349175A1 (en) * | 2021-04-29 | 2022-11-03 | G. David Schoenhard | Wall assembly |
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US20060265985A1 (en) * | 2005-05-25 | 2006-11-30 | Nichols Michael P | Insulated wall panel for building construction and method and apparatus for manufacture thereof |
US20100005746A1 (en) * | 2008-07-10 | 2010-01-14 | Dany Lemay | Insulating prefab wall structure |
US20110024432A1 (en) * | 2009-07-28 | 2011-02-03 | Jorgensen Roy W | Secondary containment system for DEF storage container |
US20110225911A1 (en) * | 2010-03-22 | 2011-09-22 | Battisti Peter L | Self-bailing interior frame |
US8621804B2 (en) | 2010-04-09 | 2014-01-07 | Materiaux Laurier Inc. | Insulating wall panel assembly and method for manufacturing same |
US20120011792A1 (en) * | 2010-07-15 | 2012-01-19 | Dewildt Dean P | High strength light-framed wall structure |
US20120151869A1 (en) * | 2010-12-20 | 2012-06-21 | United States Gypsum Company | Insulated drywall ceiling on steel "c" joists |
CN102182297A (en) * | 2011-04-08 | 2011-09-14 | 杨洪春 | Hybrid outer wall heat insulation layer construction process |
US8789338B2 (en) * | 2011-10-03 | 2014-07-29 | Johns Manville | Methods and systems for sealing a wall |
US20130081346A1 (en) * | 2011-10-03 | 2013-04-04 | Ames Kulprathipanja | Methods and systems for sealing a wall |
US9359758B2 (en) | 2011-10-03 | 2016-06-07 | Johns Manville | Methods and systems for sealing a wall |
US10081940B2 (en) * | 2012-03-13 | 2018-09-25 | Schabel Polymer Technology, Llc | Structural assembly insulation |
US20140090322A1 (en) * | 2012-03-13 | 2014-04-03 | Schabel Polymer Technology, Llc | Structural assembly insulation |
US9222254B2 (en) * | 2012-03-13 | 2015-12-29 | Schabel Polymer Technology, Llc | Structural assembly insulation |
US8978342B2 (en) | 2012-06-15 | 2015-03-17 | Auburn University | Residential radiant barrier assemblies |
FR2994992A1 (en) * | 2012-09-03 | 2014-03-07 | Jerome Maignan | Method for constructing facade of residential building, involves forming series of recesses in modules, filling recesses by heat insulator, and installing counter-partition at side of interior surface of modules |
FR2994989A1 (en) * | 2012-09-03 | 2014-03-07 | Jerome Maignan | METHOD FOR CONSTRUCTING FACADE OF PREMISES INTENDED IN PARTICULAR FOR HABITATION AND ASSOCIATED FACADE OF PREMISES |
US10626608B2 (en) | 2013-09-27 | 2020-04-21 | Covestro Llc | Foam wall structure |
US10370849B2 (en) * | 2013-09-27 | 2019-08-06 | Covestro Llc | Foam wall structure |
US20150093535A1 (en) * | 2013-09-27 | 2015-04-02 | Bayer Materialscience Llc | Foam wall structure |
USRE49073E1 (en) * | 2013-09-27 | 2022-05-17 | Covestro Llc | Foam wall structure |
US9834923B1 (en) * | 2015-08-10 | 2017-12-05 | Robert Lepage | Building construction method |
US10267030B1 (en) * | 2015-08-10 | 2019-04-23 | Robert Lepage | Building construction method |
US20220049493A1 (en) * | 2020-08-13 | 2022-02-17 | Certainteed Llc | Loose-Fill Insulated Building Structures and Methods for Making Them |
US11643810B2 (en) * | 2020-08-13 | 2023-05-09 | Certainteed Llc | Loose-fill insulated building structures and methods for making them |
US20220349175A1 (en) * | 2021-04-29 | 2022-11-03 | G. David Schoenhard | Wall assembly |
US11578483B2 (en) * | 2021-04-29 | 2023-02-14 | Back-Lattice Wall Systems, Llc | Wall assembly |
Also Published As
Publication number | Publication date |
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CA2522887A1 (en) | 2007-04-07 |
CA2562999A1 (en) | 2007-04-07 |
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