U.S. patent application number 15/613419 was filed with the patent office on 2017-12-07 for vapor retarder system.
The applicant listed for this patent is KNAUF INSULATION, INC.. Invention is credited to Jeffrey R. Brisley, Gary E. Romes.
Application Number | 20170350116 15/613419 |
Document ID | / |
Family ID | 60483017 |
Filed Date | 2017-12-07 |
United States Patent
Application |
20170350116 |
Kind Code |
A1 |
Brisley; Jeffrey R. ; et
al. |
December 7, 2017 |
VAPOR RETARDER SYSTEM
Abstract
A vapor retarder system comprises a vapor retarder and a sealant
strip. The sealant strip is adhesively coupled to the vapor
retarder to form a continuous vapor retarder.
Inventors: |
Brisley; Jeffrey R.;
(Carmel, IN) ; Romes; Gary E.; (Loveland,
OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
KNAUF INSULATION, INC. |
Shelbyville |
IN |
US |
|
|
Family ID: |
60483017 |
Appl. No.: |
15/613419 |
Filed: |
June 5, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62345954 |
Jun 6, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04B 1/7625 20130101;
E04B 1/625 20130101; E04B 1/7604 20130101; E04B 1/7076 20130101;
E04B 1/665 20130101; E04B 1/74 20130101 |
International
Class: |
E04B 1/76 20060101
E04B001/76; E04B 1/70 20060101 E04B001/70; E04B 1/66 20060101
E04B001/66 |
Claims
1. A method of insulating a wall comprising fastening a vapor
retarder to each of a first and second stud of the wall to form a
cavity therein, wherein the vapor retarder comprises a first vent
strip and a first retarder strip; inserting insulative material
into the cavity; and sealing the first vent strip with a sealant
strip, wherein the sealant strip and the first retarder strip
cooperate to form a continuous vapor retarder system that retards
vapor flow into the cavity from an external environment.
2. The method of claim 1, wherein the first vent strip is formed to
include a plurality of vent apertures configured to allow air to
pass freely between the cavity and the external environment and a
web extending between and interconnecting the plurality of vent
apertures.
3. The method of claim 2, wherein air flows out of the vent
apertures into the external environment during the step of
inserting insulative material.
4. The method of claim 3, wherein the step of inserting includes
puncturing a portion of the web to form an insertion aperture
configured to locate a nozzle therethrough.
5. The method of claim 4, wherein the method further comprises
blowing insulative material through the nozzle into the cavity.
6. The method of claim 1, wherein the vapor retarder is fastened to
each of the first and second studs with staples.
7. The method of claim 1, wherein the insulative material is loose
fill insulation.
8. The method of claim 1, wherein the vapor retarder further
comprises a second retarder strip and the first vent strip extends
between and interconnects the first retarder strip and the second
retarder strip.
9. The method of claim 1, wherein the vapor retarder further
comprises a second vent strip located in spaced-apart relation to
the first vent strip to locate the first retarder strip
therebetween.
10. The method of claim 9, wherein the step of inserting includes
puncturing the first vent strip, the second vent strip, or a
combination thereof.
11. The method of claim 1, wherein the sealant strip comprises a
backing layer and an adhesive layer.
12. The method of claim 11, wherein the sealant strip locates a
portion of the first vent strip between the backing layer and the
cavity.
13. The method of claim 11, wherein the adhesive layer comprises a
pressure-sensitive adhesive.
14. A vapor retarder system comprising a vapor retarder adapted to
be fastened to an interior surface of a structure to form a cavity,
the vapor retarder including a first vent strip and a first
retarder strip coextensive with the first vent strip; and a sealant
strip adapted to overlie to the first vent strip, wherein the
sealant strip and the first retarder strip cooperate to form a
continuous vapor retarder system that retards vapor flow into the
cavity from an external environment.
15. The vapor retarder system of claim 14, wherein the first vent
strip comprises a plurality of vent apertures.
16. The vapor retarder system of claim 15, wherein the vent
apertures are generally round.
17. The vapor retarder system of claim 15, wherein the vent
apertures are slits.
18. The vapor retarder system of claim 15, wherein the first vent
strip further comprises a web extending between and interconnecting
the plurality of vent apertures.
19. The vapor retarder system of claim 14, wherein the vapor
retarder further includes a second vent strip located in
spaced-apart relation to the first vent strip to locate the first
retarder strip therebetween.
20. An insulated wall comprising, the wall comprising a first stud
and a second stud located in spaced-apart relation to the first
stud; a vapor retarder fastened with the first stud and the second
stud and to form a cavity therein, and the vapor retarder is formed
to include a plurality of vent apertures; and a sealant strip
coupled to the vapor retarder to locate the plurality of vent
apertures between the sealant strip and the cavity, wherein the
vapor retarder and the sealant strip cooperate to retard vapor flow
between the cavity and an external environment.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of U.S.
Provisional Patent Application No. 62/345,954, filed 6 Jun. 2016,
the disclosure of which is now expressly incorporated herein by
reference.
FIELD OF THE DISCLOSURE
[0002] The present disclosure relates generally to vapor retarders
and more specifically to vapor retarder systems fastened to
interior walls of a structure.
BACKGROUND
[0003] In areas where building code requires a vapor retarder,
loose fill insulative material (fiberglass, rockwool, cellulose and
others) is installed behind netting or mesh that allows the air
generated by the blowing machine that delivers the loose fill
insulation to exhaust through the netting while the netting holds
the insulation in place. After installing the loose fill
insulation, the installer must install a vapor retarder over the
netting to form a continuous vapor retarder on the wall. This
multi-step process requires additional labor and additional
material be used to install the vapor retarder.
SUMMARY
[0004] The present disclosure may comprise one or more of the
following features and combinations thereof.
[0005] A method of insulating a wall may include providing a wall
structure and providing a vapor retarder. The wall structure may
include a first stud and a second stud each extending from a floor
to a ceiling. Each stud may be spaced-apart from one another to
form a gap therebetween. The vapor retarder may include a retarder
strip and a vent strip.
[0006] In some embodiments, the method includes fastening the vapor
retarder to each of the first and second studs to enclose the gap
and form a cavity therein. The method may further include inserting
insulative material into the cavity. In some embodiments, the
method includes sealing the vent strip with a sealant strip.
[0007] In some embodiments, the sealant strip and the retarder
strip cooperate to form a continuous vapor retarder system that
retards vapor flow into the cavity from an external
environment.
[0008] In some embodiments, the vent strip includes vent apertures
and a web. The vent apertures are configured to allow air to pass
freely between the cavity and the environment. The web extends
between and interconnects the vent apertures.
[0009] In some embodiments, air flows out of the vent apertures
into the external environment during the step of inserting
insulative material.
[0010] In some embodiments, the step of inserting includes
puncturing a portion of the web to form an insertion aperture
configured to locate a nozzle therethrough and blowing insulative
material through the nozzle into the cavity.
[0011] In some embodiments, the vapor retarder is fastened to each
of the first stud and second stud with staples. In some
embodiments, the insulative material is loose fill insulation.
[0012] In some embodiments, the vapor retarder has a first retarder
strip, a second retarder strip and the vent strip extends between
and interconnects the first retarder strip and the second retarder
strip.
[0013] According to another aspect of the present disclosure, a
vapor retarder system may include a vapor retarder and a sealant
strip. The vapor retarder may be adapted to be fastened to an
interior surface of a structure to form a cavity. The vapor
retarder may include a vent strip and a retarder strip coextensive
with the vent strip. The sealant strip may be adapted to overlie
the vent strip. The sealant strip and the retarder strip may
cooperate to form a continuous vapor retarder system that retards
vapor flow into the cavity from an external environment.
[0014] In some embodiments, the vapor retarder is coupled to a
vertical wall. In other embodiments, the vapor retarder is coupled
to a horizontal surface. In some embodiments, the vapor retarder is
coupled to a garage ceiling.
[0015] According to another aspect of the present disclosure a
method of insulating a wall may comprise fastening a vapor retarder
to each of a first and second stud of the wall to form a cavity
therein, wherein the vapor retarder comprises a first vent strip
and a first retarder strip; inserting insulative material into the
cavity; and sealing the first vent strip with a sealant strip. In
some embodiments, the sealant strip and the first retarder strip
cooperate to form a continuous vapor retarder system that retards
vapor flow into the cavity from an external environment.
[0016] In some embodiments, the first vent strip is formed to
include a plurality of vent apertures configured to allow air to
pass freely between the cavity and the external environment and a
web extending between and interconnecting the plurality of vent
apertures. In some embodiments, air flows out of the vent apertures
into the external environment during the step of inserting
insulative material.
[0017] In some embodiments, the step of inserting includes
puncturing a portion of the web to form an insertion aperture
configured to locate a nozzle therethrough.
[0018] In some embodiments, the method further comprises blowing
insulative material through the nozzle into the cavity. In some
embodiments, the vapor retarder is fastened to each of the first
and second studs with staples. In some embodiments, the insulative
material is loose fill insulation.
[0019] In some embodiments, the vapor retarder further comprises a
second retarder strip and the first vent strip extends between and
interconnects the first retarder strip and the second retarder
strip.
[0020] In some embodiments, the vapor retarder further comprises a
second vent strip located in spaced-apart relation to the first
vent strip to locate the first retarder strip therebetween. In some
embodiments, the step of inserting includes puncturing the first
vent strip, the second vent strip, or a combination thereof.
[0021] In some embodiments, the sealant strip comprises a backing
layer and an adhesive layer. In some embodiments, wherein the
sealant strip locates a portion of the first vent strip between the
backing layer and the cavity. In some embodiments, the adhesive
layer comprises a pressure-sensitive adhesive.
[0022] According to another aspect of the present disclosure, a
vapor retarder system may comprise a vapor retarder adapted to be
fastened to an interior surface of a structure to form a cavity. In
some embodiments, the vapor retarder includes a first vent strip
and a first retarder strip coextensive with the first vent strip.
In some embodiments, the vapor retarder comprises a sealant strip
adapted to overlie to the first vent strip. In some embodiments,
the sealant strip and the first retarder strip cooperate to form a
continuous vapor retarder system that retards vapor flow into the
cavity from an external environment.
[0023] In some embodiments, the first vent strip comprises a
plurality of vent apertures. In some embodiments, the vent
apertures are generally round. In some other embodiments, the vent
apertures are slits.
[0024] In some embodiments, the first vent strip further comprises
a web extending between and interconnecting the plurality of vent
apertures.
[0025] In some embodiments, the vapor retarder further includes a
second vent strip located in spaced-apart relation to the first
vent strip to locate the first retarder strip therebetween.
[0026] According to another aspect of the present disclosure, an
insulated wall may comprise the wall comprising a first stud and a
second stud located in spaced-apart relation to the first stud. In
some embodiments, the insulated wall may further comprise a vapor
retarder fastened with the first stud and the second stud and to
form a cavity therein, and the vapor retarder is formed to include
a plurality of vent apertures. In some embodiments, the insulated
wall comprises a sealant strip coupled to the vapor retarder to
locate the plurality of vent apertures between the sealant strip
and the cavity. In some embodiments, the vapor retarder and the
sealant strip cooperate to retard vapor flow between the cavity and
an external environment.
[0027] These and other features of the present disclosure will
become more apparent from the following description of the
illustrative embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is an elevation view of a vapor retarder system in
accordance with the present disclosure showing the vapor retarder
system includes a vapor retarder fastened to a wall to enclose
insulative material therein, and a sealant strip coupled to a
portion of the vapor retarder;
[0029] FIG. 2 is a sectional view taken generally along line 2-2 of
FIG. 1 showing from bottom to top the insulative material extending
between a first stud and a second stud, a vent strip comprising
vent apertures that extend through the vent strip and open into the
insulative material, and the sealant strip comprising an adhesive
layer and a backing layer coupled to the vent strip to overlie the
vent apertures;
[0030] FIG. 3 is a detail view of a portion of the vapor retarder
system of FIG. 1, showing the sealant strip overlying the vent
strip with a portion of the sealant strip peeled back to show the
underlying vent strip including an insertion aperture, the vent
apertures, and a web extending between and interconnecting the vent
apertures, and a portion of the vent strip peeled back to show the
underlying insulative material and wall structure;
[0031] FIG. 4 is an elevation view of another embodiment of a vapor
retarder system in accordance with the present disclosure, showing
that the vapor retarder system includes a first vent strip, a
second vent strip, and a first retarder strip extending between the
first and second vent strips;
[0032] FIG. 5 is an elevation view of another embodiment of a vapor
retarder system in accordance with the present disclosure, showing
that the vapor retarder system includes a first vent strip and a
second vent strip, and further showing that the vent apertures are
generally slits;
[0033] FIG. 6 is a detail view of a portion of the vapor retarder
system of FIG. 5, showing the sealant strip overlying the vent
strip with a portion of the sealant strip peeled back to show the
underlying vent strip having an insertion aperture, the slit-shaped
vent apertures, and a web extending between and interconnecting the
vent apertures, and a portion of the vent strip peeled back to show
the underlying insulative material and wall structure; and
[0034] FIG. 7 is a diagrammatic view of an illustrative embodiment
of a method of installing the vapor retarder system.
DETAILED DESCRIPTION OF THE DRAWINGS
[0035] For the purposes of promoting an understanding of the
principles of the disclosure, reference will now be made to a
number of illustrative embodiments illustrated in the drawings and
specific language will be used to describe the same.
[0036] A vapor retarder system 10 can be mounted to a wall 18 to
form an insulated wall 11, as shown in FIG. 1. The vapor retarder
system 10 can provide an insulative value to the wall while also
retarding the flow of vapor from an external environment. The vapor
retarder system 10 includes a vapor retarder 14 adapted to be
fastened to the wall 18. When fastened to the wall 18, the vapor
retarder 14 is configured to vent excess pressure during a step of
blowing an insulative material 12 into a cavity 28 formed between
the vapor retarder 14 and the wall 18. A sealant strip 16 can then
be applied to the vapor retarder 14 to prevent the flow of vapor
between the cavity 28 and an external environment. A second
embodiment of a vapor retarder system 210 is shown in FIG. 4. A
third embodiment of a vapor retarder system is shown in FIGS. 5 and
6. A method 100 of installing a vapor retarder system 10 is shown
in FIG. 7.
[0037] The vapor retarder system 10 includes the insulative
material 12, the vapor retarder 14, sometimes called a ventable
vapor retarder 14, and the sealant strip 16, as shown in FIGS. 1
and 3. The insulative material 12 provides an insulative value to
the insulated wall 11. The ventable vapor retarder 14 fastens to
the wall 18 to locate the insulative material 12 therein. The
sealant strip 16 couples to a portion of the ventable vapor
retarder 14. The sealant strip 16 cooperates with the ventable
vapor retarder 14 to retard the flow of vapor through the vapor
system 10.
[0038] The wall 18 includes a first stud 20 and a second stud 21
that each extend from a floor or sill plate 22 to a ceiling or top
plate 24, as shown in FIG. 1. The first stud 20 and the second stud
21 cooperate to form a gap therebetween.
[0039] The ventable vapor retarder 14 couples to the wall 18 to
enclose the gap and form a cavity 28, as shown in FIGS. 1-3. The
ventable vapor retarder 14 includes a vent strip 30 and at least
one retarder strip 32 as shown in FIG. 1. The vent strip 30 allows
air to be released from the cavity 28 during an insulating
operation. The retarder strip 32 retards the flow of vapor through
a portion of the vapor retarder 14. In an embodiment, the ventable
vapor retarder 14 has first retarder strip 32 and a second retarder
strip 44 located in spaced-apart relation to the first retarder
strip 32. In the illustrative embodiment, the vent strip 30 extends
between and interconnects the first and second retarder strips 32,
44, as shown in FIGS. 1 and 3. Illustratively, the ventable vapor
retarder 14 is fastened to the wall 18 with staples 33 into the
first and second studs 20, 21. Illustratively, the vent strip spans
the distance between the first and second studs 20, 21.
[0040] The sealant strip 16 adheres to the ventable vapor retarder
14 and includes an adhesive layer 34 and a backing layer 36, as
shown in FIG. 2. The adhesive layer 34 extends between and
interconnects the backing layer 36 and the ventable vapor retarder
14. The backing layer 36 is configured to retard the flow of vapor
therethrough.
[0041] In an embodiment, the sealant strip 16 is a tape that
adheres to the ventable vapor retarder 14. In another embodiment,
the sealant strip 16 is a continuous piece of plastic that adheres
to the ventable vapor retarder 14. In another embodiment, the
sealant strip 16 is any type of material qualifying as a vapor
retarder of 1 perm or less. The sealant strip 16 cooperates with
the ventable vapor retarder 14 to form a continuous vapor block
that prevents or minimizes the flow of vapor.
[0042] The vent strip 30 is configured to allow pressure venting
during a blown insulation process. The vent strip 30 is formed to
include the vent apertures 38 and a web 40, as shown in FIGS. 2 and
3. The vent apertures 38 are configured to allow air to pass freely
between the cavity 28 and the environment. The web 40 extends
between and interconnects the vent apertures 38 and provides at
least a portion of a surface that couples to the sealant strip 16,
as shown in FIG. 2. In an embodiment, the vent strip 30 is parallel
to the floor or sill plate 22.
[0043] The vent strip 30 can have a range of widths that are
illustratively generally measured in a direction that is
perpendicular to the floor 22. The width of the vent strip 30 may
be one of the following values: about 4 inches, about 6 inches,
about 8 inches, about 10 inches, about 12 inches, about 15 inches,
about 16 inches, about 20 inches, about 24 inches, about 28 inches,
or about 30 inches wide. The vent strip 30 may be about 4 inches to
about 30 inches, about 6 inches to about 30 inches, about 8 inches
to about 30 inches, about 12 inches to about 30 inches about 12
inches to about 24 inches, or about 12 inches to about 18 inches
wide. In an illustrative embodiment, the vent strip is about 6
inches wide. In another illustrative embodiment, the vent strip 30
is about 12 inches wide. In yet another illustrative embodiment,
the vent strip 30 is about 18 inches wide.
[0044] In some embodiments, each aperture 38 of the vent apertures
38 is generally circular, as shown in FIGS. 1 and 3.
Illustratively, each of the apertures 38 can be about 0.25 inches
in diameter and be spaced about 3 inches apart. In another
embodiment, each aperture is about 0.5 inches in diameter. While
circular apertures 38 are illustratively described herein, any
suitable shape or spacing of the plurality of apertures 38 that
sufficiently allow escape of blown air may be used in the vent
strip 30. In another embodiment, each aperture 38 of the plurality
of apertures 38 has an irregular shape.
[0045] The apertures 38 are located in spaced-apart relation to one
another, as shown in FIGS. 1-3. In a vertical direction, each
aperture may be about 0.1 inches, about 0.25 inches, about 0.5
inches, about 0.75 inches, about 1 inch, about 1.25 inches, about
1.5 inches, about 1.75 inches, about 2 inches, about 2.5 inches, or
about 3 inches away from a neighboring aperture 38. In some
embodiments, each vent aperture can be about 0.1 inches to about 3
inches, about 0.5 inches to about 3 inches, about 0.5 inches to
about 2.5 inches, about 0.5 inches to about 2 inches, about 0.75
inches to about 2 inches, or about 1 inch to about 3 inches away
from a neighboring aperture 38.
[0046] The apertures 38 are located in spaced-apart relation to one
another, as shown in FIGS. 1-3. In a horizontal direction, each
aperture may be about 0.1 inches, about 0.25 inches, about 0.5
inches, about 0.75 inches, about 1 inch, about 1.25 inches, about
1.5 inches, about 1.75 inches, about 2 inches, about 2.5 inches, or
about 3 inches away from a neighboring aperture 38. In some
embodiments, each vent aperture can be about 0.1 inches to about 3
inches, about 0.5 inches to about 3 inches, about 0.5 inches to
about 2.5 inches, about 0.5 inches to about 2 inches, about 0.75
inches to about 2 inches, or about 1 inch to about 3 inches away
from a neighboring aperture 38.
[0047] The insulative material 12 is located within the cavity 28,
as shown in FIGS. 1-3. In an embodiment, the insulative material 12
is loose fill insulation such as fiberglass, rockwool, cellulose or
any other suitable loose fill insulation. The insulative material
12 cooperates with the structure of the wall 18 to provide an
insulative value. In some embodiments, the vapor retarder system 10
provides an insulative value of about R-5 to about R-49, about R-5
to about R-35, about R-5 to about R-15, or about R-15 to about
R-35.
[0048] The vapor retarder system 10 retards the flow of vapor
between the cavity 28 and an external environment. In some
embodiments, the external environment is an interior room of a
structure and the vapor retarder system 10 is located between the
interior room of the structure and an exterior of the structure. In
some embodiments, the vapor retarder system 10 is located between
the interior room of the structure and the first and second studs
20, 21, as shown in FIG. 1. In some embodiments, the external
environment is outside of the structure and the vapor retarder
system is located between the exterior of the structure and the
first and second studs 20, 21. In some embodiments, the vapor
retarder system 10 retards the flow of vapor from the cavity 28
into the interior room of the structure. The vapor retarder system
10 can provide a perm rating of less than about 3, less than about
2, less than about 1, less than about 0.8, less than about 0.5, or
less than about 0.3.
[0049] In some embodiments, the ventable vapor retarder 14
comprises a polyethylene film. The thickness of the ventable vapor
retarder 14 may be one of the following values: about 1 mil to
about 10 mils, about 1 mil to about 8 mils, about 2 mils to about 8
mils, about 3 mils to about 8 mils, about 4 mils to about 8 mils,
and about 4 mils to about 7 mils. The thickness of the ventable
vapor retarder 14 may be one of the following values, about 1 mil,
about 2 mils, about 3 mils, about 4 mils, about 5 mils, about 6
mils, about 7 mils, about 8 mils, about 9 mils, and about 10 mils.
In an embodiment, the ventable vapor retarder 14 is about 6 mils
thick.
[0050] In another embodiment in accordance with the present
disclosure, the ventable vapor retarder 14 can be installed on a
horizontal surface. Illustrative horizontal surfaces include garage
ceilings and floors.
[0051] During the preparation of the insulated wall 11, a
technician may insert a fill nozzle into the first vent strip 30
and form an insertion aperture 42, as shown in FIG. 1. The
technician may then add insulative material 12 to the cavity 28. In
some embodiments, a technician may insert a fill nozzle into the
first retarder strip 32. If a technician inserts a fill nozzle into
the first retarder strip 32, a patch may be applied to the vapor
retarder 14 to seal the aperture formed in the first retarder strip
32.
[0052] Another illustrative vapor retarder system 210 adapted for
use on a wall is shown in FIG. 4. The vapor retarder system 210 is
substantially similar to the vapor retarder system 10 shown in
FIGS. 1-3 and described herein. Accordingly, similar reference
numbers in the 200 series indicate features that are common between
the vapor retarder system 10 and the vapor retarder system 210. The
description of the vapor retarder system 10 is hereby incorporated
by reference to apply to the vapor retarder system 210, except in
instances when it conflicts with the specific description and
drawings of the vapor retarder system 210.
[0053] The vapor retarder system 210 includes the insulative
material 212, the vapor retarder 214, sometimes called a ventable
vapor retarder 214, and the sealant strip 216, as shown in FIG. 4.
Illustratively, the first sealant strip 216 couples to a portion of
the ventable vapor retarder 214 and cooperates with the ventable
vapor retarder 214 to retard the flow of vapor through the vapor
retarder system 210.
[0054] The vapor retarder 214 comprises a first vent strip 230, a
second vent strip 231, and a first retarder strip 232 as shown in
FIG. 4. The first vent strip 230 is located in spaced-apart
relation to the second vent strip 231. Illustratively, the first
vent strip 230 is located between the first retarder strip 232 and
the top plate 224. The second vent strip 231 is located between the
first vent strip 230 and the sill plate 222. The first retarder
strip 232 extends between and interconnects the first vent strip
230 and the second vent strip 231.
[0055] In some embodiments, the vapor retarder 214 comprises a
second retarder strip 244 and a third retarder strip 245 located in
spaced-apart relation to the second retarder strip 244, as shown in
FIG. 4. The second retarder strip 244 is located between the first
vent strip 230 and the top plate 224. The third retarder strip 245
is located between the second vent strip 231 and the sill plate
222.
[0056] The insulative material 212 provides an insulative value to
the insulated wall 211. The ventable vapor retarder 214 fastens to
the wall 218 to locate the insulative material 212 therein. The
insulative material 212 is located within the cavity 228, as shown
in FIG. 4 In an embodiment, the insulative material 212 is loose
fill insulation such as fiberglass, rockwool, cellulose or any
other suitable loose fill insulation. The insulative material 212
cooperates with the structure of the wall 218 to provide an
insulative value. In some embodiments, the vapor retarder system
210 provides an insulative value of about R-5 to about R-49, about
R-5 to about R-35, about R-5 to about R-15, or about R-15 to about
R-35.
[0057] In some embodiments, the vapor retarder system 210 comprises
a first sealant strip 216 and a second sealant strip 217, as shown
in FIG. 4. Each of the first and second sealant strips 216, 217
adhere to the vapor retarder 214. Each of the first and second
sealant strips 216, 217 include an adhesive layer 234 and a backing
layer 236. The adhesive layer 234 extends between and interconnects
the backing layer 236 and the ventable vapor retarder 214. In an
embodiment, the first and second sealant strips 216, 217 are each a
continuous piece of plastic adhered to the ventable vapor retarder
214. In another embodiment, the sealant strips 216, 217 comprise
any type of material qualifying as a vapor retarder of 1 perm or
less. The sealant strips 216, 217 cooperate with the ventable vapor
retarder 214 to form a continuous vapor retarder.
[0058] Illustratively, the first sealant strip 216 is configured to
locate the first vent strip 230 between the backing layer 236 of
the first sealant strip and the cavity 228, as shown in FIG. 4. The
second sealant strip 217 is configured to locate the second vent
strip 231 between the backing layer 236 of the second sealant strip
217 and the cavity 228. Illustratively, the first and second
sealant strips 216 cooperate with the first, second, and third
retarder strips 232, 244, 245 to form a continuous barrier against
vapor transmission.
[0059] During the preparation of the insulated wall 211, a
technician may insert a fill nozzle into the first vent strip 230,
the second vent strip 231, or both the first and second vent strips
230, 231 and form an insertion aperture 242. The technician may
then add insulative material 212 to the cavity 228.
[0060] In some embodiments, a technician may insert a fill nozzle
into the first retarder strip 232. If a technician inserts a fill
nozzle into the first retarder strip 232, a patch may be applied to
the vapor retarder 214 to seal the aperture formed in the first
retarder strip 232.
[0061] Another illustrative vapor retarder system 310 adapted for
use on a wall is shown in FIGS. 5-6. The vapor retarder system 310
is substantially similar to the vapor retarder system 10 shown in
FIGS. 1-3 and described herein. Accordingly, similar reference
numbers in the 300 series indicate features that are common between
the vapor retarder system 10 and the vapor retarder system 310. The
description of the vapor retarder system 10 is hereby incorporated
by reference to apply to the vapor retarder system 310, except in
instances when it conflicts with the specific description and
drawings of the vapor retarder system 310.
[0062] The vapor retarder system 310 includes the insulative
material 312, the vapor retarder 314, sometimes called a ventable
vapor retarder 314, and the first sealant strip 316, as shown in
FIGS. 5-6. Illustratively, the first sealant strip 316 couples to a
portion of the ventable vapor retarder 314 and cooperates with the
ventable vapor retarder 314 to retard the flow of vapor through the
vapor retarder system 310.
[0063] The vapor retarder 314 comprises a first vent strip 330, a
second vent strip 331, and a first retarder strip 332 as shown in
FIG. 5. The first vent strip 330 is located in spaced-apart
relation to the second vent strip 331. Illustratively, the first
vent strip 330 is located between the second vent strip 331 and the
top plate 324. The second vent strip 331 is located between the
first vent strip 330 and the sill plate 322. The first retarder
strip 332 extends between and interconnects the first vent strip
330 and the second vent strip 331.
[0064] The insulative material 312 provides an insulative value to
the insulated wall 211. The ventable vapor retarder 314 fastens to
the wall 318 to locate the insulative material 312 therein. The
insulative material 312 is located within the cavity 328, as shown
in FIG. 5 In an embodiment, the insulative material 312 is loose
fill insulation such as fiberglass, rockwool, cellulose or any
other suitable loose fill insulation. The insulative material 312
cooperates with the structure of the wall 318 to provide an
insulative value. In some embodiments, the vapor retarder system
310 provides an insulative value of about R-5 to about R-49, about
R-5 to about R-35, about R-5 to about R-15, or about R-15 to about
R-35.
[0065] In some embodiments, the vapor retarder 314 comprises a
second retarder strip 344 and a third retarder strip 345 located in
spaced-apart relation to the second retarder strip 344, as shown in
FIG. 5. The second retarder strip 344 is located between the first
vent strip 330 and the top plate 324. The third retarder strip 345
is located between the second vent strip 331 and the sill plate
322. The insulative material 312 provides an insulative value to
the insulated wall 311. The ventable vapor retarder 314 fastens to
the wall 318 to locate the insulative material 312 therein. A
sealant strip 316 couples to a portion of the ventable vapor
retarder 314 and cooperates with the vapor retarder 314 to retard
the flow of vapor.
[0066] In some embodiments, the vapor retarder system 310 comprises
a first sealant strip 316 and a second sealant strip 317, as shown
in FIG. 5. Each of the first and second sealant strips 316, 317
adhere to the vapor retarder 314. Each of the first and second
sealant strips 316, 317 include an adhesive layer 334 and a backing
layer 336. The adhesive layer 334 extends between and interconnects
the backing layer 336 and the ventable vapor retarder 314. In an
embodiment, the first and second sealant strips 316, 317 are each a
continuous piece of plastic adhered to the ventable vapor retarder
314. In another embodiment, the first and second sealant strips
316, 317 comprise any type of material qualifying as a vapor
retarder of 1 perm or less. The first and second sealant strips
316, 317 cooperate with the ventable vapor retarder 314 to form a
continuous vapor retarder.
[0067] Illustratively, the first sealant strip 316 is configured to
locate the first vent strip 330 between the backing layer 336 of
the first sealant strip and the cavity 328, as shown in FIGS. 5 and
6. The second sealant strip 317 is configured to locate the second
vent strip 331 between the backing layer 336 of the second sealant
strip 317 and the cavity 328. Illustratively, the first and second
sealant strips 316, 317 cooperate with the first, second, and third
retarder strips 332, 344, 345 to form a continuous barrier against
vapor transmission.
[0068] In an embodiment, each aperture of the vent apertures 338 is
a slit, as shown in FIGS. 5 and 6. The apertures 338 may be
generally parallel to the sill plate 322, generally perpendicular
to the sill plate 322, generally diagonal to the sill plate 322, a
mixture thereof, or oriented in a random direction relative to the
sill plate 322. Illustratively, each of the apertures can be about
0.25 inches, about 0.5 inches, about 0.75 inches, about 1 inch,
about 1.25 inches, about 1.5 inches, about 1.75 inches, about 2
inches, about 2.5 inches, or about 3 inches long. In some
embodiments, each vent aperture can be about 0.25 inches to about 3
inches, about 0.5 inches to about 3 inches, about 0.5 inches to
about 2.5 inches, about 0.5 inches to about 2 inches, about 0.75
inches to about 2 inches, or about 1 inch to about 3 inches
long.
[0069] The apertures 338 are located in spaced-apart relation
vertically to one another, as shown in FIG. 5. In a vertical
direction, each aperture may be about 0.1 inches, about 0.25
inches, about 0.5 inches, about 0.75 inches, about 1 inch, about
1.25 inches, about 1.5 inches, about 1.75 inches, about 2 inches,
about 2.5 inches, or about 3 inches away from a neighboring
aperture 338. In some embodiments, each vent aperture can be about
0.1 inches to about 3 inches, about 0.5 inches to about 3 inches,
about 0.5 inches to about 2.5 inches, about 0.5 inches to about 2
inches, about 0.75 inches to about 2 inches, or about 1 inch to
about 3 inches away from a neighboring aperture 338.
[0070] The apertures 338 are located in spaced-apart relation
horizontally to one another, as shown in FIG. 5. In a horizontal
direction, each aperture may be about 0.1 inches, about 0.25
inches, about 0.5 inches, about 0.75 inches, about 1 inch, about
1.25 inches, about 1.5 inches, about 1.75 inches, about 2 inches,
about 2.5 inches, or about 3 inches away from a neighboring
aperture 338. In some embodiments, each vent aperture can be about
0.1 inches to about 3 inches, about 0.5 inches to about 3 inches,
about 0.5 inches to about 2.5 inches, about 0.5 inches to about 2
inches, about 0.75 inches to about 2 inches, or about 1 inch to
about 3 inches away from a neighboring aperture 338.
[0071] During the preparation of the insulated wall 311, a
technician may insert a fill nozzle into the first vent strip 330,
the second vent strip 331, or both the first and second vent strips
330, 331 and form an insertion aperture 342. The technician may
then add insulative material 312 to the cavity 328.
[0072] In some embodiments, a technician may insert a fill nozzle
into the first retarder strip 332. If a technician inserts a fill
nozzle into the first, second, or third retarder strips 332, 344,
345 a patch may be applied to the vapor retarder 314 to seal the
aperture formed in the first retarder strip 332.
[0073] A method 100 of insulating a wall 18 is shown
diagrammatically in FIG. 7. In an embodiment, the method 100
includes providing 110 the wall 18. In some embodiments, the method
100 further includes providing 120 the ventable vapor retarder 14
comprising the vent strip 30 and at least one retarder strip 32, as
shown in FIGS. 1-3. While some illustrative steps for method 100
are described for vapor retarder system 10, the method 100 applies
with equal weight to vapor retarder systems 210, 310.
[0074] The method 100 further includes fastening 130 the ventable
vapor retarder 14 to the wall 18 to enclose the gap between the
first and second studs 20, 21 to form the cavity 28 therein as
shown in FIG. 3. Illustratively, the ventable vapor retarder 14 is
stapled to each of the first stud 20 and the second stud 21 with
staples 33 to retain the ventable vapor retarder 14 on the wall
throughout the method 100.
[0075] The method 100 further includes inserting 140 a fill nozzle
into the vent strip 30 to form an insertion aperture 42 as shown in
FIGS. 1 and 3. In some embodiments, the fill nozzle is inserted
into the retarder strip 32.
[0076] The method further includes inserting 150 insulative
material through the fill nozzle into the cavity 28. During the
inserting 150 step, insulative material 12 is blown into the cavity
28 causing a pressure increase in the cavity 28. The excess
pressure in the cavity 28 is able to escape the cavity 28 and pass
into the environment through the vent apertures 38 of the vent
strip 30. The method further comprises removing 160 the fill nozzle
from the filled cavity 28.
[0077] The length of time for the step of inserting 150 the
insulative material 12 may be dependent on the size of the cavity
28, the feed ratio of the air pressure and insulative material 12,
and the duration of the step of inserting 150. Illustratively, the
length of time for the step of inserting 150 may also dependent on
the desired level of R-value for the insulated wall 11. In some
embodiments, the step of inserting is performed for about 10
seconds, about 15 seconds, about 30 seconds, about 35 seconds,
about 40 seconds, about 45 seconds, about 1 min, about 1.5 minutes,
about 2 minutes, about 3 minutes, about 4 minutes, about 5 minutes,
about 7 minutes, about 10 minutes or about 20 minutes. In some
embodiments, the step of inserting is performed for about 10
seconds to about 20 minutes, about 30 seconds to about 10 minutes,
about 30 seconds to about 5 minutes, or about 1 minute to about 5
minutes.
[0078] In some embodiments, the insulative material 12 is inserted
into the cavity 28 at about 1 lb/30 seconds, about 1.5 lbs/30
seconds, about 2 lbs/30 seconds, about 2.5 lbs/30 seconds, about 3
lbs/30 seconds, about 3.5 lbs/30 seconds, about 4 lbs/30 seconds,
about 4.5 lbs/30 seconds, about 5 lbs/30 seconds, about 5.5 lbs/30
seconds, about 6 lbs/30 seconds, about 6.5 lbs/30 seconds, about 7
lbs/30 seconds, about 8 lbs/30 seconds, about 9 lbs/30 seconds, or
about 10 lbs/30 seconds. In some embodiments, the insulative
material 12 is inserted into the cavity 28 at a rate of about 1
lb/30 seconds to about 10 lbs/30 seconds, about 1 lb/30 seconds to
about 8 lbs/30 seconds, about 2 lbs/30 seconds to about 8 lbs/30
seconds, about 2 lbs/30 seconds to about 7 lbs/30 seconds, or about
3 lbs/30 seconds to about 7 lbs/30 seconds.
[0079] In some embodiments, the method 100 further comprises
inserting 140 the fill nozzle into a second vent strip 231. In some
embodiments, the method 100 comprises inserting the fill nozzle
into a first vent strip 230 before inserting the fill nozzle into
the second vent strip 231. In some embodiments, the method 100
comprises inserting the fill nozzle into the second vent strip 231
before inserting the fill nozzle into the first vent strip 230. In
some embodiments, the second vent strip 231 is located between the
first vent strip 230 and the sill plate 222. In some embodiments,
the first vent strip 230 is located between the second vent strip
231 and the top plate 224.
[0080] The method further comprises sealing 170 the vent strip 30
with the sealant strip 16. The sealing 170 step locates the vent
apertures 38 and the insertion aperture 42 between the sealant
strip 16 and the insulative material 12 to retard vapor flow
therethrough. Illustratively, the sealing 170 step forms the
continuous vapor retarder. In an embodiment, the sealing step 170
includes applying an adhesive layer 34 to the ventable vapor
retarder 14 and applying the backing layer 36 to the ventable vapor
retarder 14. In some embodiments, the sealant strip 16 comprises a
pressure sensitive adhesive and the step of sealing 170 includes
applying the pressure-sensitive adhesive backed sealant strip 16 to
the vapor retarder 14.
[0081] Loose fill insulation (fiberglass, rockwool, cellulose and
others (e.g. insulative material 12) has long been installed behind
netting or mesh that allows the air generated by the blowing
machine that delivers the loose fill insulation to exhaust through
the netting and hold the insulation in place behind the netting.
Unfortunately, in climate zones where the building code requires a
vapor retarder (e.g. vapor retarder system 10) be installed, the
applicator must then install a vapor retarder over the netting.
This process requires additional labor and additional material are
used to install the vapor retarder. In general, it is a very
inefficient method of installing the loose fill insulation (e.g.
insulative material 12) when a vapor retarder is required.
[0082] After the cavities (e.g. cavity 28) have been filled with
insulation (e.g. insulative material 12), the installers quickly
seal the vented channel (e.g. vent strip 30) using a pressure
sensitive tape (e.g. sealant strip 16), small sheet of poly adhered
by spray adhesive, or any number of different types of material
that has a minimum of 1 permanence rating.
[0083] The Integrated Vapor Retarder/Netting System (e.g. the
ventable vapor retarder 14 and the sealant strip 16) may be more
efficient and cost effective for the contractor, builder, and
homeowner because it eliminates the additional cost of the vapor
retarder material and additional labor to install the vapor
retarder.
[0084] While the disclosure has been illustrated and described in
detail in the foregoing drawings and description, the same is to be
considered as exemplary and not restrictive in character, it being
understood that only illustrative embodiments thereof have been
shown and described and that all changes and modifications that
come within the spirit of the disclosure are desired to be
protected.
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