U.S. patent application number 11/688793 was filed with the patent office on 2007-09-20 for wall forms for spraying insulation.
Invention is credited to Jonathan Sherner.
Application Number | 20070214739 11/688793 |
Document ID | / |
Family ID | 38516283 |
Filed Date | 2007-09-20 |
United States Patent
Application |
20070214739 |
Kind Code |
A1 |
Sherner; Jonathan |
September 20, 2007 |
Wall Forms for Spraying Insulation
Abstract
A panel system is provided to form a barrier and an enclosed
cavity for spraying foam insulation. The panel system may use panel
sections removably attached together to achieve a desired length.
The panel sections are attached to wall studs and foam insulation
is sprayed into the resulting cavity. After the foam has reacted,
the panels may be removed and reused in another section. In one
embodiment, a plastic sheet is used as a barrier between the panel
and the foam insulation, which sheet can later be removed.
Inventors: |
Sherner; Jonathan;
(Billings, MT) |
Correspondence
Address: |
HUSCH & EPPENBERGER, LLC
190 CARONDELET PLAZA
SUITE 600
ST. LOUIS
MO
63105-3441
US
|
Family ID: |
38516283 |
Appl. No.: |
11/688793 |
Filed: |
March 20, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60767337 |
Mar 20, 2006 |
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Current U.S.
Class: |
52/309.9 ;
52/742.13 |
Current CPC
Class: |
E04B 2/562 20130101;
E04B 1/7604 20130101 |
Class at
Publication: |
052/309.9 ;
052/742.13 |
International
Class: |
E04B 1/00 20060101
E04B001/00; E04C 1/00 20060101 E04C001/00 |
Claims
1. A panel for spray foam insulation comprising: a first panel
section adapted for attachment to a wall stud; a second panel
section adapted for attachment to a wall stud; wherein said first
panel section is removably attached to said second section.
2. A panel for spray foam insulation according to claim 1, wherein
said first panel section further comprises: a hole adapted for
insertion of a tip of a spray foam gun.
3. A panel for spray foam insulation according to claim 1, wherein
said first panel section is removably attached to said second panel
section using screws.
4. A panel for spray foam insulation according to claim 1, wherein
said first panel section further comprises: a frame; and mesh
attached to said frame.
5. A panel for spray foam insulation according to claim 1, wherein
said first panel section further comprises: a plastic panel; and a
plurality of tabs extending from said plastic panel.
6. A method for using panels for spray foam insulation comprising:
attaching a first panel section to a second panel section to form a
resultant panel section; attaching said resultant panel section to
a wall section; inserting a tip of a spray gun through said
resultant panel; and applying foam through said spray gun.
7. A method according to claim 4, further comprising: attaching a
plastic sheet to a wall section before said step of attached said
resultant panel section to a wall section; and inserting a tip of a
spray gun through said plastic sheet panel after said step of
inserting a tip of a spray gun through said resultant panel.
8. A method according to claim 4, wherein said step of attaching
said resultant panel section to a wall section comprises screwing
said resultant panel section to a wall section.
9. A method according to claim 4, wherein said step of attaching
said resultant panel section to a wall section comprises disposing
a base across said resultant panel section and inserting screws
through said base to said wall section.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. provisional patent
application No. 60/767337, filed Mar. 20, 2006.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable.
APPENDIX
[0003] Not Applicable.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention
[0006] 2. Related Art
[0007] Spraying foam insulation is a complicated process. The foam
ingredients must be mixed, heated, and then pressurized. The foam
is then sprayed onto walls to fill various areas such as gaps,
cracks, and spaces between wall studs.
[0008] When the foam is sprayed onto a surface, the foam begins to
expand. After drying, the dried foam is trimmed flush to various
surfaces. For example, when foam is sprayed between wall studs, the
dried foam is trimmed so that the outer surface of the foam is
flush with the outer surface of a wall stud.
[0009] The trimming operation takes time in the form of trimming
time, and cleanup time in collecting the trimmed waste.
SUMMARY OF THE INVENTION
[0010] The present invention is a panel system that enables foam
insulation to be sprayed in a way that minimizes trimming and
waste. In the invention, a panel section is provided that is used
to contain an open space between wall sections. Optionally, a
plastic sheet may be used for attaching across the open face of a
cavity to serve as a barrier between the spray foam insulation and
a panel.
[0011] Further areas of applicability of the present invention will
become apparent from the detailed description provided hereinafter.
It should be understood that the detailed description and specific
examples, while indicating the preferred embodiment of the
invention, are intended for purposes of illustration only and are
not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The present invention will become more fully understood from
the detailed description and the accompanying drawings,
wherein:
[0013] FIG. 1 is a front view of the panel of the present
invention;
[0014] FIG. 2 is a side view of the panel of the present
invention;
[0015] FIG. 3 is an elevated view of an inside corner of a
house;
[0016] FIG. 4 is an elevated view of the placement of panels into
an inside corner of FIG. 3;
[0017] FIG. 5 is an elevated view of retaining means being applied
to the panels of FIG. 4;
[0018] FIG. 6 is an elevated view of screws being applied to the
panels of FIG. 4;
[0019] FIG. 7 is an elevated assembly view of a plastic sheet and
panel, as applied to the corner of FIG. 4;
[0020] FIG. 8 is a perspective view of an alternative panel
embodiment; and
[0021] FIG. 9 is a perspective view of an alternative panel
embodiment of the panel in FIG. 8.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] The following description of the preferred embodiment(s) is
merely exemplary in nature and is in no way intended to limit the
invention, its application, or uses.
[0023] In FIG. 1, a panel shown generally at 10 is provided.
Preferably, the panel has a width that corresponds to standard
widths between studs, namely, 12, 18, 24 32 and 48 inches.
[0024] Panel 10 comprises a panel frame 14. Panel frame 14 is
preferably made from flat aluminum or metal strips. Between the
strips of panel frame 14, a mesh 16 is provided. Panel 10 is
preferably provided with handle 18 for ease of handling.
Preferably, panel 10 may be 96 inches in length, although it is
recognized that panel length will vary according to need.
[0025] It will be appreciated that panel 10, for practical reasons,
will come in various standard lengths. These lengths may be
cumbersome for storage and transportation. Accordingly, these
panels may be provided with means for combining multiple sections
together. In the present invention, these panel sections may be
provided with a hinge section, whereby multiple sections can be
removably and pivotably attached by a hinge. For travel and
storage, the hinge pin can be removed, and the sections can be more
easily stored and carried.
[0026] The panel 10 is used in combination with plastic sheet 20,
to form a cavity between a wall and studs. In essence, the panel 10
and plastic sheet 20 form a barrier to prevent spray foam
insulation from expanding past the surface of wall studs. First, as
shown in FIG. 3, plastic sheeting 20 is attached to wall framing
and studs 22.
[0027] Next, panel 10 is removably attached to wall stud using
screws and a drill. In particular, wood or some other suitable
material may be used as shown in FIGS. 5-6 as a base 24 for
applying screws 26 through the base 24, through the panel mesh 16,
through plastic sheet 20, and through wall stud 22. Multiple panels
10 are butted together.
[0028] The cavity formed by panels 10 and wall studs 22 is then
filled with spray foam. In particular, the tip of a foam spray gun
(not shown) may be inserted through a hole in the mesh 16, and
punched through plastic sheet 20. The plastic sheet 20 is used as a
non-adhering barrier between the panel 10 and the sprayed foam
insulation.
[0029] After the spray foam insulation has reacted and filled the
cavity, the panels 10 may be removed. Then, plastic sheet 20 may be
removed at any time and discarded. Plastic sheet 20 is preferably
removed by pulling one edge of the sheet.
[0030] Then, the process repeats by applying new plastic sheeting
20 to an uninsulated wall section, and removably attaching the old
panels to wall studs to form additional cavities. Next, the process
of filling the cavity with spray foam insulation is repeated.
[0031] After the plastic sheet is removed, the open foamed surface
remains. This surface may be finished by brushing with a wire
brush.
[0032] In an alternative embodiment shown in FIGS. 8 and 9, panel
10 may be made in sections from a smooth plastic, and provided with
holes 40. In this alternative embodiment, panel 10 is made in a
unit form. Multiple panel 10 units may be pieced together to form a
long panel length by inserting screws (not shown) through holes 40.
Then, holes 42 in tab 44 are used to fix panel 10 to wall stud.
FIG. 9 shows an alternative panel 10, similar to the panel 10 in
FIG. 8, wherein an additional lip 46 is provided to provide a more
secure fit with wall stud 22. It is important to note that holes 40
at the top end (relative to an installed panel 10) may also serve
as an access point for the insertion of the foam gun tip, although
an additional hole (not shown) may also be provided for that
purpose.
[0033] In use, in the alternative embodiments, no plastic sheet is
used. Instead, the plastic panel 10 is applied directly to the wall
stud 22 by applying a screw through hole 42 in tab 44. Then, the
foam is applied through hole 40, or a different hole provided for
this purpose, and the cavity is filled with foam insulation. After
the foam has reacted, panel 10 may be removed and re-used by
repeating the above process.
[0034] As various modifications could be made to the exemplary
embodiments, as described above with reference to the corresponding
illustrations, without departing from the scope of the invention,
it is intended that all matter contained in the foregoing
description and shown in the accompanying drawings shall be
interpreted as illustrative rather than limiting. For example, it
should be appreciated that various dimensions of the various parts
of the panel will necessarily vary according to need and the
availability of materials. Thus, the breadth and scope of the
present invention should not be limited by any of the
above-described exemplary embodiments, but should be defined only
in accordance with the following claims appended hereto and their
equivalents.
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