U.S. patent application number 15/722144 was filed with the patent office on 2018-03-22 for building insulation system.
The applicant listed for this patent is Owens Corning Intellectual Capital, LLC. Invention is credited to Larry J. Grant, Glenn Haley, John W. Hoffman, Katrina J. Keeley, Daryl P. Wernette.
Application Number | 20180080223 15/722144 |
Document ID | / |
Family ID | 54835697 |
Filed Date | 2018-03-22 |
United States Patent
Application |
20180080223 |
Kind Code |
A1 |
Grant; Larry J. ; et
al. |
March 22, 2018 |
BUILDING INSULATION SYSTEM
Abstract
Insulated building wrap for use on a building wall includes
fiberglass insulation laminated to a building wrap material. A
building wall that includes the building wrap includes framing
studs, an interior wallboard secured to the framing studs, cavity
insulation between pairs of the framing studs, exterior sheathing
secured to the framing studs, the insulated building wrap, and a
decorative external fascia disposed over the insulated building
wrap.
Inventors: |
Grant; Larry J.;
(Westerville, OH) ; Keeley; Katrina J.;
(Westerville, OH) ; Wernette; Daryl P.;
(Johnstown, OH) ; Hoffman; John W.; (New Albany,
OH) ; Haley; Glenn; (Granville, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Owens Corning Intellectual Capital, LLC |
Toledo |
OH |
US |
|
|
Family ID: |
54835697 |
Appl. No.: |
15/722144 |
Filed: |
October 2, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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14719447 |
May 22, 2015 |
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15722144 |
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|
62011890 |
Jun 13, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04B 1/7662 20130101;
E04B 2/707 20130101; E04B 1/625 20130101 |
International
Class: |
E04B 1/62 20060101
E04B001/62; E04B 1/76 20060101 E04B001/76; E04B 2/70 20060101
E04B002/70 |
Claims
1-20. (canceled)
21. A building wall comprising: a plurality of framing studs; an
interior wallboard secured to the framing studs; cavity insulation
positioned between pairs of the framing studs; exterior sheathing
secured to the framing studs; an insulated building wrap secured to
an exterior surface of the exterior sheathing; and a decorative
external fascia disposed over the insulated building wrap; wherein
the insulated building wrap includes fiberglass insulation
laminated to a building wrap material, wherein the fiberglass
insulation is binderless and has an R value greater than or equal
to 4 per inch, and wherein the insulated building wrap is flexible
enough to be rolled onto a roll.
22. The building wall of claim 21, wherein the insulated building
wrap has a compressive strength at 25% deformation of the
fiberglass insulation which is less than 100 lbs/ft.sup.2.
23. The building wall of claim 21, wherein the insulated building
wrap does not crack when bent over a 1.6 mm diameter mandrel at a
temperature of 32.degree. F.
24. The building wall of claim 21, wherein a loss on ignition of
the insulated building wrap is less than 10%.
25. The building wall of claim 21, wherein a loss on ignition of
the insulated building wrap is less than 5%.
26. The building wall of claim 21, wherein the insulated building
wrap has an R value of greater than or equal to 4.5 per inch.
27. The building wall of claim 21, wherein the insulated building
wrap has an R value of greater than or equal to 5 per inch.
28. The building wall of claim 21, wherein the insulated building
wrap has an R value of greater than or equal to 7 per inch.
29. The building wall of claim 21, wherein the insulated building
wrap has an R value between 4 per inch and 7.5 per inch.
30. The building wall of claim 21, wherein the insulated building
wrap has a thickness between 0.5 inches and 1.5 inches.
31. A building wall comprising: a plurality of framing studs; an
interior wallboard secured to the framing studs; cavity insulation
positioned between pairs of the framing studs; exterior sheathing
secured to the framing studs; an insulated building wrap secured to
an exterior surface of the exterior sheathing; and a decorative
external fascia disposed over the insulated building wrap; wherein
the insulated building wrap includes fiberglass insulation
laminated to a building wrap material, wherein the fiberglass
insulation is binderless and has an R value greater than or equal
to 4 per inch, and wherein the insulated building wrap does not
crack when bent over a 1.6 mm diameter mandrel at a temperature of
32.degree. F.
32. The building wall of claim 31, wherein the insulated building
wrap has a compressive strength at 25% deformation of the
fiberglass insulation which is less than 100 lbs/ft.sup.2.
33. The building wall of claim 31, wherein a loss on ignition of
the insulated building wrap is less than 10%.
34. The building wall of claim 31, wherein a loss on ignition of
the insulated building wrap is less than 5%.
35. The building wall of claim 31, wherein the insulated building
wrap has an R value of greater than or equal to 4.5 per inch.
36. The building wall of claim 31, wherein the insulated building
wrap has an R value of greater than or equal to 5 per inch.
37. The building wall of claim 31, wherein the insulated building
wrap has an R value of greater than or equal to 7 per inch.
38. The building wall of claim 31, wherein the insulated building
wrap has an R value between 4 per inch and 7.5 per inch.
39. The building wall of claim 31, wherein the insulated building
wrap has a thickness between 0.5 inches and 1.5 inches.
Description
RELATED APPLICATIONS
[0001] The present application is a continuation of U.S.
application Ser. No. 14/719,447, filed May 22, 2015 titled
"BUILDING INSULATION SYSTEM", which claims the benefit of U.S.
provisional patent application No. 62/011,890, filed on Jun. 13,
2014, titled "Building Insulation System", the entire disclosures
of which are incorporated herein by reference in their
entirety.
BACKGROUND
[0002] 1) Field of the Invention
[0003] The present application relates to an insulated building
wrap that seals the exterior of a building from moisture and air
permeation, while still allowing water vapor to escape.
[0004] 2) Description of Related Art
[0005] Water resistant film or sheet materials are known to be
useful in the construction industry, for preventing the
infiltration of air and water to the interior of a building while
allowing the outward passage there through of moisture vapor. Such
materials may be flexible and used as building "wraps," or may be
rigid and used as structural or decorative panels in the exterior
walls or roofs of buildings.
[0006] Prior art FIG. 1 illustrates an example of a building wall
10. The illustrated building wall includes and interior wallboard
12, framing studs 14, cavity insulation 16, exterior sheathing 18,
house wrap or building wrap 20, and a decorative external fascia
22. The interior wallboard 12 may be a gypsum based material, such
as drywall. The framing studs 14 may be wooden studs or metal
studs. The cavity insulation 16 may be provided in the form of a
batt or blanket or may be blown-in insulation. The exterior
sheathing 18 may be wood, such as particle boards of wood panels.
Other exterior sheathings 18, such as extruded polystyrene or
polyisocyanurate insulated foam boards, provide increased R-value
external to the home, and in some cases, can act as a weatherizing
barrier.
[0007] Building wrap 20 reduces energy loss through reduction of
air infiltration as well as acting as a weather barrier by
preventing water intrusion into the building. It is a requirement
that these materials are breathable. One popular material that is
manufactured for building wrap is PinkWRAP.RTM. from Owens Corning.
PinkWRAP.RTM. Housewrap is a woven polyolefin fabric engineered to
be a weather resistant barrier. PinkWRAP.RTM. Housewrap reduces the
air infiltration through residential and commercial exterior side
wall construction.
[0008] PinkWRAP.RTM. Housewrap has microperforations that permit
trapped moisture to escape from the wall to the exterior.
PinkWRAP.RTM. Housewrap is translucent to allow installers to see
the framing underneath. PinkWRAP.RTM. Housewrap has excellent
tensile strength and tear resistance to withstand installation and
wind driven loads. PinkWRAP.RTM. Housewrap can be left uncovered
for up to 300 days before siding is installed. PinkWRAP.RTM.
Housewrap meets the requirements of a weather resistant barrier as
defined by ICC-ES Acceptance Criteria AC 38. See ICC Evaluation
Services ESR 2801. PinkWRAP.RTM. Housewrap has the following
properties.
TABLE-US-00001 Property Test Method Actual Required Tensile
Strength ASTM D 828 60/44 20/20 (lbs/in., MD/CD) Trapezoidal ASTM D
1117 37/49 -- Tear Strength (lbs., MD/CD) Water Resistance ASTM D
779 >60 10 minute (10 min. minimum) Minimum Water Vapor ASTM E
96- 52 >35 Transmission Rate Procedure A (g/m2/24 hrs) Dry Cup
(75 F; 50% RH) Water Vapor ASTM E 96- 7.7 >5 Permeance Procedure
A Rate (perms) Dry Cup (75 F; 50% RH) Fire Characteristics- ASTM E
84 5 <25 Flame Spread Fire Characteristics- ASTM E 84 30 <450
Smoke Application Ambient exposure 9 N/A Exposure (months)
[0009] Another material that is manufactured for housewrap is a
flash spunbonded polyolefin that may be obtained from DuPont under
the name Tyvek.TM.. Another material is a microporous polyolefin
film composite and may be obtained from Simplex Products under the
trademark "R-Wrap.TM." There are a variety of other brands such as
Typar.RTM. from Reemay, Amowrap.RTM. from Teneco building products,
Barricade.RTM. from Simplex, and others.
[0010] Porous polyolefin films composites are used in building wrap
applications. Building wrap 20 materials are permeable to gases as
to allow water vapor to escape from the wall to which the film is
secured. The film is also sufficiently impervious to air to
insulate the wall against wind and water intrusion. Further, the
film has adequate tensile and physical properties such as break
strength, elongation, tear strength, shrinkage and puncture
strength to avoid damage during installation.
[0011] Porous polyolefin films may be prepared by stretching a
precursor film filled with calcium carbonate. "Breathable" films
which are gas/vapor permeable and liquid impermeable have been
described in U.S. Pat. No. 4,472,328, assigned to Mitsubishi
Chemical Industries, Ltd, which is incorporated here by reference
in its entirety. The Mitsubishi patent describes a breathable
polyolefin film prepared from a polyolefin/filler composition
having from 20 percent to 80 percent by weight of a filler such as
a surface treated calcium carbonate. A liquid or waxy hydrocarbon
polymer elastomer such as a hydroxy-terminated liquid polybutadiene
was found to produce a precursor film that could be monoaxially or
biaxially stretched to make a film breathable.
[0012] Providing a proper weather barrier material allows energy
efficient buildings to be constructed. Currently, the majority of
the heat that escapes a residential home exits through the floor,
walls, and ceilings. For maximized energy efficiency, the Model
Energy Code of the Council of American Building Officials calls for
walls and ceilings to be insulated to R19 and R38 respectively.
Current "2 by 4" wall construction allows for 3.5'' of fiberglass
insulation, which is rated at R-11. Housewraps are widely used as a
weatherizing membrane to block both water and air from penetrating
into the home structure, while still allowing water vapor to
escape.
SUMMARY
[0013] The present application discloses an insulated building wrap
that includes fiberglass insulation laminated to a building wrap
material. In one exemplary embodiment, the insulated building wrap
is substantially impervious to air, substantially impervious to
water, and is permeable to water vapor. In one exemplary
embodiment, the fiberglass insulation is binderless or
substantially binderless. In one exemplary embodiment, the
insulated building wrap includes a grooved surface that assists
drainage.
[0014] The insulated building wrap can be used in a variety of
different applications. In one exemplary embodiment, the insulated
building wrap is used in a building wall. For example, a building
wall may include framing studs, an interior wallboard secured to
the framing studs, cavity insulation between pairs of the framing
studs, exterior sheathing secured to the framing studs, the
insulated building wrap, and a decorative external fascia disposed
over the insulated building wrap.
[0015] Various objects and advantages will become apparent to those
skilled in the art from the following detailed description of the
invention, when read in light of the accompanying drawings. It is
to be expressly understood, however, that the drawings are for
illustrative purposes and are not to be construed as defining the
limits of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a perspective view of a prior art building
wall;
[0017] FIG. 2 is a perspective view of an exemplary embodiment of a
building wall with an insulated building wrap;
[0018] FIG. 3 is an end view of an exemplary embodiment of an
insulated building wrap;
[0019] FIG. 3A is an end view of an exemplary embodiment of an
insulated building wrap;
[0020] FIG. 3B is an end view of an exemplary embodiment of an
insulated building wrap;
[0021] FIG. 3C is an end view of an exemplary embodiment of an
insulated building wrap;
[0022] FIG. 4 is an end view of an exemplary embodiment of an
insulated building wrap;
[0023] FIG. 5 is an illustration of an exemplary embodiment of a
roll of insulated building wrap;
[0024] FIG. 6 is a perspective view of a building wall illustrating
installation of an insulated building wrap;
[0025] FIG. 7 is a plan view of an exemplary embodiment of an
insulated building wrap with installation flanges;
[0026] FIG. 8 is a sectional view illustrating installation of an
insulated building wrap with mounting flanges on a wall;
[0027] FIG. 9 is a sectional view illustrating installation of an
insulated building wrap with installation flanges on a wall;
[0028] FIG. 10 is a perspective view of two exterior building walls
with one having a window opening;
[0029] FIG. 11 illustrates an exemplary embodiment of a window
installation;
[0030] FIG. 12 is a sectional view illustrating an exemplary
embodiment of an insulated building wrap installed on a wall;
[0031] FIG. 13A is a sectional view illustrating installation of an
insulated building wrap with mounting flanges;
[0032] FIG. 13B is an enlarged version of FIG. 13A;
[0033] FIG. 14A is a sectional view illustrating installation of an
insulated building wrap with mounting flanges;
[0034] FIG. 14B is an enlarged version of FIG. 14A;
[0035] FIG. 15 is a front view of an exemplary embodiment of an
insulated building wrap with cuts that form mounting tabs and
mounting flanges;
[0036] FIG. 16A is a front view of the insulated building wrap of
FIG. 15 with the mounting flanges folded down;
[0037] FIG. 16B is a view taken along the plane indicated by lines
16B-16B in FIG. 16A;
[0038] FIG. 17A is a sectional view illustrating installation of an
insulated building wrap with mounting tabs and mounting flanges;
and
[0039] FIG. 17B is a sectional view illustrating installation of an
insulated building wrap with mounting tabs and mounting
flanges.
DETAILED DESCRIPTION OF THE INVENTION
[0040] The present invention will now be described with occasional
reference to the specific embodiments of the invention. This
invention may, however, be embodied in different forms and should
not be construed as limited to the embodiments set forth herein.
Rather, these embodiments are provided so that this disclosure will
be thorough and complete, and will fully convey the scope of the
invention to those skilled in the art.
[0041] Unless otherwise defined, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which this invention belongs. The
terminology used in the description of the invention herein is for
describing particular embodiments only and is not intended to be
limiting of the invention. As used in the description of the
invention and the appended claims, the singular forms "a," "an,"
and "the" are intended to include the plural forms as well, unless
the context clearly indicates otherwise.
[0042] Unless otherwise indicated, all numbers expressing
quantities of dimensions such as length, width, height, and so
forth as used in the specification and claims are to be understood
as being modified in all instances by the term "about."
Accordingly, unless otherwise indicated, the numerical properties
set forth in the specification and claims are approximations that
may vary depending on the desired properties sought to be obtained
in embodiments of the present invention. Notwithstanding that the
numerical ranges and parameters setting forth the broad scope of
the invention are approximations, the numerical values set forth in
the specific examples are reported as precisely as possible. Any
numerical values, however, inherently contain certain errors
necessarily resulting from error found in their respective
measurements.
[0043] Referring to FIG. 2 an exemplary embodiment of a building
wall 10 includes an interior wallboard 12, framing studs 14, cavity
insulation 16, exterior sheathing 18, insulated building wrap 220,
and a decorative external fascia 22. The interior wallboard 12 may
be a gypsum based material, such as drywall. However, any material
may be used as the interior wallboard. An optional vapor barrier 13
may be provided on the interior side of the framing studs 14. The
framing studs 14 may be wooden studs or metal studs. However, any
material may be used as the framing studs. The cavity insulation 16
may be provided in the form of a batt or blanket or may be blown-in
insulation. Any type of cavity insulation 16 may be used. The
exterior sheathing 18 may be wood, such as particle boards of wood
panels. Other exterior sheathings 18, such as extruded polystyrene
or polyisocyanurate insulated foam boards, provide increased
R-value external to the home, and in some cases, can act as a
weatherizing barrier. Any type of exterior sheathing 18 can be
used. The decorative external fascia 22 can take a wide variety of
different forms. Examples of decorative external fascia include,
but are not limited to, brick, stone, and siding.
[0044] The insulated building wrap 220 can take a wide variety of
different forms. Referring to FIG. 3, in one exemplary embodiment,
the insulated building wrap 220 includes fiberglass insulation 224
and building wrap material 222 on one side of the fiberglass
insulation. FIG. 4 illustrates another exemplary embodiment where
building wrap material 222 is disposed on both sides of the
fiberglass insulation 224.
[0045] In one exemplary embodiment, the fiberglass insulation 224
is configured to perform the functions described herein of both the
fiberglass insulation 224 and the building wrap material 222. For
example, the insulation material 224 itself may be permeable to
water vapor and may thus be considered as breathable while
remaining substantially impervious to air and water such that wind
and rain does not pass through. The building wrap material 222 may
be omitted or substantially omitted when the insulation material
224 is so constructed. FIGS. 3A, 3B, and 3C illustrate exemplary
embodiments where the building wrap material is omitted or
substantially omitted. In the FIG. 3A embodiment, the building wrap
material 222 is completely omitted. In the FIG. 3B embodiment, the
building wrap 220 includes one or more nailing or securing
reinforcements 350. The nailing or securing reinforcements 350 may
be made of a building wrap material 222 or some other reinforcing
material. In the FIG. 3C embodiment, the building wrap 220 includes
one or more nailing or securing tabs 360. The nailing or securing
tabs 360 may be made of a building wrap material 222 or some other
material. The nailing or securing reinforcements 350 or the nailing
or securing tabs 360 may be provided in strips along one or more
edges of the insulation material 224 or at discrete locations. The
nailing or securing reinforcements 350 or the nailing or securing
tabs 360 are strong enough to hold a fastener (not shown) and
support the building wrap 220 on a wall 10.
[0046] The fiberglass insulation 224 can take a wide variety of
different forms. In one exemplary embodiment, the fiberglass
insulation 224 is made in accordance with one or more of US
Published Patent Application Pub. Nos. 2013/0084445 published on
Apr. 4, 2013, titled "Method of Forming a Web from Fibrous
Material" and 2013/0266784 published on Oct. 10, 2013 and titled
"Method of Forming a Web from Fibrous Material." US Published
Patent Application Pub. Nos. 2013/0084445 and 2013/0266784 are
incorporated herein by reference in their entirety.
[0047] In one exemplary embodiment, the fiberglass insulation 224
is a compressible fiberglass insulation. Examples of compressible
fiberglass insulation 224 that may be used are disclosed by US
Published Patent Application Pub. Nos. 2013/0084445 and
2013/0266784. However, other forms of fiberglass insulation 224 may
also be used.
[0048] In one exemplary embodiment, the fiberglass insulation 224
has a high compressibility (i.e. a low compressive strength). As a
result, the insulated building housewrap 220 has a high
compressibility (i.e. a low compressive strength). In one exemplary
embodiment, the fiberglass insulation 224 is made in accordance
with teachings of US Published Patent Application Pub. Nos.
2013/0084445 and/or 2013/0266784 and has a high compressibility
(i.e. a low compressive strength). In one exemplary embodiment, the
compressive strength at 25% deformation of the fiberglass
insulation 224 is less than 100 lbs/ft.sup.2, such as less than 75
lbs/ft.sup.2, such as less than 50 lbs/ft.sup.2, such as from 20 to
50 lbs/ft.sup.2. In one exemplary embodiment, the fiberglass
insulation 224 is made in accordance with teachings of US Published
Patent Application Pub. Nos. 2013/0084445 and/or 2013/0266784 and
the compressive strength at 25% deformation of the fiberglass
insulation 224 is less than 100 lbs/ft.sup.2, such as less than 75
lbs/ft.sup.2, such as less than 50 lbs/ft.sup.2, such as from 20 to
50 lbs/ft.sup.2. Tables 1A-4B provide examples of compressive
strengths of samples of fiberglass insulation 224 made in
accordance with teachings of US Published Patent Application Pub.
Nos. 2013/0084445 and/or 2013/0266784 with the specifications
listed in the tables.
TABLE-US-00002 TABLE 1A Com- pressive Load @ Strength @ Thickness
25% 25% Specimen @ 25% De- De- Specimen Weight Thickness De-
formation formation # (g.) (in.) formation (6'' .times. 6'')
(lbs./ft..sup.2) 1 19.03 0.58 0.44 8.6185 34.474 2 22.43 0.63 0.47
9.4291 37.717 3 26.65 0.67 0.50 12.4012 49.605 4 27.73 0.69 0.52
12.5827 50.331 Average 23.96 0.64 0.48 10.758 St. Dev. 4.00 0.05
0.04 2.031 8.123
TABLE-US-00003 TABLE 1B Com- pressive Load @ Strength @ Thickness
25% 25% Specimen @ 25% De- De- Specimen Weight Thickness De-
formation formation # (g.) (in.) formation (6'' .times. 6'')
(lbs./ft..sup.2) 1 29.31 0.71 0.53 10.840 43.358 2 23.11 0.63 0.47
10.112 40.446 3 20.51 0.59 0.44 10.553 42.213 4 19.97 0.63 0.47
8.553 34.210 Average 23.23 0.64 0.48 10.014 St. Dev. 4.28 0.05 0.04
1.019 4.078
TABLE-US-00004 TABLE 2A Com- pressive Load @ Strength @ Thickness
25% 25% Specimen @ 25% De- De- Specimen Weight Thickness De-
formation formation # (g.) (in.) formation (6'' .times. 6'')
(lbs./ft..sup.2) 1 34.50 0.95 0.71 7.8651 31.460 2 32.17 0.90 0.68
8.4093 33.637 3 29.62 0.85 0.64 8.5531 34.212 4 30.09 0.89 0.67
8.0239 32.096 Average 31.60 0.90 0.67 8.213 St. Dev. 2.23 0.04 0.03
0.322 1.288
TABLE-US-00005 TABLE 2B Com- pressive Load @ Strength @ Thickness
25% 25% Specimen @ 25% De- De- Specimen Weight Thickness De-
formation formation # (g.) (in.) formation (6'' .times. 6'')
(lbs./ft..sup.2) 1 34.13 0.96 0.72 7.890 31.558 2 27.85 0.83 0.62
8.239 32.956 3 32.29 0.91 0.68 8.061 32.244 4 28.41 0.96 0.72 5.706
22.823 Average 30.67 0.92 0.69 7.474 St. Dev. 3.04 0.06 0.05 1.187
4.749
TABLE-US-00006 TABLE 3A Com- pressive Load @ Strength @ Thickness
25% 25% Specimen @ 25% De- De- Specimen Weight Thickness De-
formation formation # (g.) (in.) formation (6'' .times. 6'')
(lbs/ft..sup.2) 1 33.52 0.93 0.70 6.1204 24.482 2 35.96 0.99 0.74
7.9529 31.812 3 34.11 0.95 0.71 9.6042 38.417 4 35.58 0.95 0.71
9.7260 38.904 Average 34.79 0.96 0.72 8.351 St. Dev. 1.16 0.03 0.02
1.693 6.771
TABLE-US-00007 TABLE 3B Com- pressive Load @ Strength @ Thickness
25% 25% Specimen @ 25% De- De- Specimen Weight Thickness De-
formation formation # (g.) (in.) formation (6'' .times. 6'')
(lbs./ft..sup.2) 1 31.03 0.90 0.68 7.665 30.661 2 34.93 0.90 0.68
9.133 36.530 3 33.99 0.88 0.66 9.978 39.912 4 29.71 0.86 0.65 9.028
36.114 Average 32.42 0.89 0.66 8.951 St. Dev. 2.45 0.02 0.01 0.957
3.827
TABLE-US-00008 TABLE 4A Com- pressive Load @ Strength @ Thickness
25% 25% Specimen @ 25% De- De- Specimen Weight Thickness De-
formation formation # (g.) (in.) formation (6'' .times. 6'')
(lbs/ft..sup.2) 1 32.2 1.00 0.75 6.0569 24.228 2 38.37 1.05 0.79
6.3847 25.539 3 31.99 0.95 0.71 6.8701 27.480 4 33.87 1.04 0.78
6.5109 26.044 Average 34.11 1.01 0.76 6.456 St. Dev. 2.96 0.05 0.03
0.336 1.344
TABLE-US-00009 TABLE 4B Com- pressive Load @ Strength @ Thickness
25% 25% Specimen @ 25% De- De- Specimen Weight Thickness De-
formation formation # (g.) (in.) formation (6'' .times. 6'')
(lbs./ft..sup.2) 1 30.14 1.00 0.75 5.411 21.643 2 27.79 1.00 0.75
5.130 20.518 3 30.01 0.96 0.72 6.193 24.772 4 31.85 0.98 0.74 6.594
26.374 Average 29.95 0.99 0.74 5.832 St. Dev. 1.66 0.02 0.01 0.679
2.714
[0049] In one exemplary embodiment, the fiberglass insulation 224
is a flexible fiberglass insulation and the insulated building wrap
220 is flexible. The insulation 224 and the finished insulated
building wrap may be both flexible and compressible as described
above. In one exemplary embodiment, the fiberglass insulation 224
is flexible enough to be wound onto a roll 500 (See FIG. 5).
Examples of flexible fiberglass insulation 224 that may be used are
disclosed by US Published Patent Application Pub. Nos. 2013/0084445
and 2013/0266784.
[0050] In one exemplary embodiment, the insulated building wrap 220
is pliable. For example, the insulated building wrap 220 is pliable
in accordance with the method described in Section 3.3.4 of ICC-ES
AC 38 in one exemplary embodiment. According to this test method,
five 25.4 mm*203 mm sections of the insulated building housewrap
are cut in both the roll and cross roll directions. They are
maintained at 0.degree. C. for 24 hours before being bent
180.degree. over a 1.6 mm diameter mandrel. The samples passed the
pliability tests when the sample did not crack at 0.degree. C.
(-32.degree. F.).
[0051] In one exemplary embodiment, the insulated building wrap 220
is more resistant to burning than an insulated building wrap that
includes and insulation material made from a polymer. In one
exemplary embodiment, the loss on ignition (LOI) of the insulated
building wrap 220 is less than or equal to the weight of the
building wrap material 222 divided by the total weight of the
insulated building wrap 220 (the weight of the wrap material 222
plus the weight of the fiberglass insulation 224). In one exemplary
embodiment, the LOI of the insulated building wrap 220 is less than
10%, for example 5-8%. In one exemplary embodiment, the LOI of the
insulated building wrap 220 is between 1 and 5%. In one exemplary
embodiment, the LOI of the insulated building wrap 220 is less than
5% and the fiberglass insulation 222 is made in accordance with
teachings of US Published Patent Application Pub. Nos. 2013/0084445
and/or 2013/0266784. In one exemplary embodiment, the LOI of the
insulated building wrap 220 is between 1 and 5% and the fiberglass
insulation 222 is made in accordance with teachings of US Published
Patent Application Pub. Nos. 2013/0084445 and/or 2013/0266784. In
one exemplary embodiment, the fiberglass insulation is binderless.
In one exemplary embodiment, the fiberglass insulation is
binderless and the fiberglass insulation 222 is made in accordance
with teachings of US Published Patent Application Pub. Nos.
2013/0084445 and/or 2013/0266784.
[0052] The fiberglass insulation 224 may be constructed to have a
variety of different thermal insulation R values. In one exemplary
embodiment, the fiberglass insulation 224 has a thermal insulation
R value of at least 4R per inch, with a preferred R value of 4.5 or
above. In one exemplary embodiment, the fiberglass insulation 224
has a thermal insulation R value of about 5R per inch or above,
such as 4.88 R per inch or above. The thickness of the fiberglass
insulation 224 may be from 0.5 to 1.5 inches. As such, the R value
of the insulated building wrap 222 is up to about 7.5 in one
exemplary embodiment. In one exemplary embodiment, the R value of a
one-half inch thick insulated building wrap 220 is about 2.5 or
above. In one exemplary embodiment, the R value of a one and
one-half inch thick insulated building wrap 220 is about 7 or
above. In one exemplary embodiment, fiberglass insulation 224 is
made in accordance with teachings of US Published Patent
Application Pub. Nos. 2013/0084445 and/or 2013/0266784 and has R
values as disclosed therein.
[0053] In one exemplary embodiment, the fiberglass insulation 224
is configured to drain water. In one exemplary embodiment, a
one-inch thick, twelve inch tall sample, having a width W drains
greater than 25 gallons per hour per lineal foot of the width W.
For example, such a sample may drain greater than 50 gallons per
hour per lineal foot of the width W. This drainage is measured by
providing a one inch head on top of the one inch by W (width) inch
top end of the sample.
[0054] In an exemplary embodiment, the insulated building wrap 220
includes building wrap material 222 that is permeable to water
vapor attached to fiberglass insulation 224. The building wrap
material is permeable to water vapor and may thus be considered as
breathable while remaining substantially impervious to air and
water such that wind and rain does not pass through. In some
embodiments, the building wrap material 222 is a polymeric or
cellulosic material. The building wrap material 222 may have a wide
range of thicknesses. For example, the thickness of the building
wrap material 222 may be from about 0.25 mils to about 1000
mils.
[0055] As explained above, the breathable building wrap material
222 is substantially impervious to air and water while permeable to
water vapor. The breathable building wrap material 222 may be a
polymeric material or a cellulosic material. Optionally, the
breathable building wrap material 222 may comprise fibers or a
fibrous material which provides a support to the material.
[0056] The building wrap material 222 may be an existing housewrap
20 material, such as PinkWrap.RTM. from Owens Corning, Typar.RTM.
from Reemay, Spun bonded polyolefins like Tyvek.RTM. from Dupont,
Amowrap.RTM. from Teneco building products, Barricade.RTM. and
R-wrap.RTM. from Simplex.
[0057] In one exemplary embodiment, the building wrap material 222
includes drainage features. The drainage features may take a wide
variety of different forms. In one exemplary embodiment, the
building wrap material 222 includes a grooved surface. The grooved
surface assists in drainage between the insulated building wrap 220
and the decorative external fascia 22, when all or portion of the
building wrap 222 are against the decorative external fascia. This
contact may occur between the insulated building wrap 220 and the
decorative external fascia 22, where contact did not occur between
conventional housewrap and the decorative external fascia 22 due to
the increased thickness of the insulated building wrap.
[0058] The water vapor permeation of the building wrap material 222
may be designed to be either bidirectional or unidirectional.
Depending on the circumstance and in a building envelope, for most
of the cases, it is very important to get any water vapor from the
inside to the outside environment and not the other way around.
However, in some cases, it may be desirable to have
bidirectionality of water permeation. Unidirectionality may be
provided by the characteristics of the water building wrap material
222 used.
[0059] The building wrap material 222 may comprise a polyolefin and
preferably a polyethylene, polypropylene or polybutylene. The
building wrap material 222 may be prepared from continuous fibers
of such materials using a flash spinning followed by bonding with
heat and pressure. Other materials like polystyrene, expanded
polystyrene, polyester, acrylic, polycarbonate, fluoropolymers,
fluorinated urethane, PTFE, expanded PTFE, phenol-formaldehyde,
melamine-formaldehyde, a phenolic resin, or copolymers thereof,
individually or in combinations can be used to manufacture the
building wrap material 222. Building wrap material can be in the
form of a microporous composite such as PinkWrap.RTM. from Owens
Corning or RWrap.TM. obtained from Simplex products.
[0060] The building wrap material 222 and fiberglass insulation 224
can be combined in several ways. Examples of ways the building wrap
material 222 and the fiberglass insulation 224 can be combined to
make the insulated building wrap 220 include, without limitation,
lamination, wrapping, shrink wrapping, etc. Lamination can be
performed with an adhesive, a resin, a heat treatment or
combinations thereof. The laminations may be extrusion, adhesive,
flame, ultrasonic or thermal based. When an adhesive is used, the
adhesive may be a hot melt adhesive or a water based adhesive.
However, other types of adhesives may also be used. One challenge
in combining the building wrap material 222 with fiberglass
insulation 224 is ensuring that the moisture vapor is still allowed
to escape, while eliminating penetration of water and air. In one
exemplary embodiment, the adhesive is a breathable adhesive. That
is, the adhesive may be a solid material that is breathable, like
the building wrap material 222.
[0061] In one exemplary embodiment, the lamination of the building
wrap material 222 to the fiberglass insulation 224 allows the
fiberglass insulation 224 to be cleanly or substantially completely
peeled away from the building wrap material 222. This is
particularly useful in areas, such as doors and windows where it is
desirable to remove the fiberglass insulation 224 from the building
wrap in a pattern that matches the shape of the door or window. In
an exemplary embodiment, the clean peel nature of the insulated
building wrap is due to the brittleness of the glass fibers. The
fiber to fiber entangled bonds of glass fibers can separate very
near the building wrap material, allowing the vast majority of the
fiberglass insulation 224 to be peeled away from the building wrap
material.
[0062] Referring to FIG. 4, in one exemplary embodiment, the
building wrap material 222 is disposed on both sides of the
fiberglass insulation 224. The building wrap material 222 on both
sides of the fiberglass insulation may take a wide variety of
different forms. The building wrap material 222 may be the same
material on both sides of the fiberglass insulation 224 or the
building wrap material 222 on one side of the fiberglass insulation
224 may be different than the building wrap material 222 on the
other side of the insulation material 224. For example, the
building wrap material 222 on one side of the fiberglass insulation
224 may have a different permeability than the building wrap
material 222 on the other side of the insulation material 224.
[0063] In some exemplary embodiments, the building wrap material
222 and/or fiberglass insulation 224 may include additional
materials. Additional materials that may be included in the
building wrap material 222 and/or fiberglass insulation 224
include, but are not limited to, polyethylene, polypropylene,
polybutylene polystyrene, expanded polystyrene, polyester, acrylic;
polycarbonate, fluoropolymers, fluorinated urethane, PTFE, expanded
PTFE, phenol-formaldehyde, melamine-formaldehyde, a phenolic resin,
or copolymers thereof, carbon, carbon black, titania, iron oxides,
gypsum and cellulosic material including paper.
[0064] Referring to FIGS. 6-8, in one exemplary embodiment the
insulated building material includes one or more installation
flanges 600. In the illustrated embodiment, installation flanges
are included on all four edges 602, 604, 606, and 608 of the
insulated building wrap. However, the installation flanges 600 may
be included on one, two, or three of the edges 602, 604, 606. 608.
For example, the insulation flanges 600 may be included on the top
and bottom edges 602, 604 only or only on the side edges 606,
608.
[0065] The installation flanges 600 can take a wide variety of
different forms. In one exemplary embodiment, the installation
flanges 600 are formed by extending the building wrap material 222
past the edges of the fiberglass insulation. As such, there is no
insulation 224 behind the insulation flanges 600.
[0066] In one exemplary embodiment, one or more of the installation
flanges 600 include markings 620 that aid alignment of fasteners,
such as screws, nails, staples, etc. with the framing studs 14. For
example, framing studs are typically located on 16 inch or 24 inch
centers. In one exemplary embodiment, markings 620 are provided on
top and/or bottom flanges every eight inches to provide alignment
aids for studs on 16 inch or 24 inch centers.
[0067] Referring to FIG. 6, the insulated building wrap 220 may be
installed on a building wall 10 in a wide variety of different
ways. In one exemplary embodiment, one or more of the installation
flanges 600 are attached to the building wall 10 to attach the
insulated building wrap 220. For example, a top flange 630 and one
or more side flanges 632 may be attached to the building wall. The
flanges 600 may be attached to the wall in a wide variety of
different ways. For example, the flanges 600 may be attached to the
building wall with fasteners, such as nails, screws, capscrews,
staples, and the like, adhesives, including pre-applied adhesives,
and adhesives applied at the building site, tape, such as flashing
tape, etc. In one exemplary embodiment where adhesives are used to
attach the installation flanges 600 to the wall and/or to an
adjacent insulated building wrap, a peel and stick adhesive and/or
a spray adhesive may be used. One acceptable peel and stick
adhesive is Vaproseal. One acceptable spray adhesive is 3M Super 77
spray adhesive.
[0068] In one exemplary embodiment, rather than using an adhesive
to attach the installation flanges 600 to adjacent insulated
building wrap, similar or dissimilar polymers may be provided on
each side of the building wrap material 222. The polymers may be
selected such that the application of heat or pressure bonds the
joints together. For example, the back surface of the installation
flanges 600 may bond to the front surface of the building wrap
material 222 to bond the two adjacent insulated building wraps
together. This works like tape or an adhesive, but a separate tape
or adhesive is not required. For example, the installation flanges
600 may be made from polypropylene and/or polyester. In one
exemplary embodiment, the flanges 600 are point bonded together
with pressure and no heat. In another exemplary embodiment, the
flanges are heat welded together.
[0069] In one exemplary embodiment, the one or more of the
installation flanges 600 include pre-installed fasteners, such as
screws, nails, staples, etc. Some or all of the pre-installed
fasteners can be pre-aligned with the framing studs 14. The
insulated building wrap 220 with the pre-installed fasteners can be
provided on a roll 500. The insulated building wrap 220 can simply
be unrolled and installed on the wall with the pre-installed
fasteners and optionally, some or all of the pre-installed
fasteners are aligned with the framing studs 14 once a first of the
fasteners is aligned and/or secured to the framing studs. For
example, framing studs are typically located on 16 inch or 24 inch
centers. Pre-installed nails or screws can be provided on 8 inch,
16 inch or 24 inch centers. Optional additional staples that do not
need to be aligned with the studs 14 can also be pre-applied in the
installation flanges.
[0070] Referring to FIG. 8, in one exemplary embodiment, the
installation flanges 600 are configured to provide a seal between
adjacent insulated building wrap 220 sections. For example, the
flanges 600 may provide seals between building wrap sections 220
that are positioned above and below one another or laterally next
to one another. In the example illustrated by FIG. 8, a top flange
630 of a lower insulated building wrap section 800 is attached to
the wall 10. A bottom flange 634 of an upper insulated building
wrap section 810 is adhered to the lower insulated building wrap
section 800 to provide a seal therebetween. Insulated building wrap
220 sections that are next to one another can be sealed together in
a similar manner. A side flange 632 of a first insulated building
wrap section is attached to the wall and a side flange 632 of a
second, adjacent building wrap section is adhered to the first
insulated building wrap section to seal the two together. This
installation process is repeated vertically and laterally to cover
the building with the insulated building housewrap 220.
[0071] FIG. 9 illustrates another exemplary embodiment where the
installation flanges 600 are configured to provide a seal between
adjacent insulated building wrap 220 sections. The embodiment of
FIG. 9 differs from the embodiment of FIG. 8 in that the one or
more of the edges 602, 604, 606, and 608 are tapered to provide an
overlap of the fiberglass insulation 224 sections. The flanges 600
may provide seals between building wrap sections 220 that are
positioned above and below one another or laterally next to one
another. In the example illustrated by FIG. 9, a top flange 630 of
a lower insulated building wrap section 900 is attached to the wall
10. A bottom flange 634 of an upper insulated building wrap section
910 is adhered to the lower insulated building wrap section 900 to
provide a seal therebetween. Insulated building wrap 220 sections
that are next to one another can be sealed together in a similar
manner. A side flange 632 of a first insulated building wrap
section is attached to the wall and a side flange 632 of a second,
adjacent building wrap section is adhered to the first insulated
building wrap section to seal the two together. This installation
process is repeated vertically and laterally to cover the building
with the insulated building housewrap 220.
[0072] Referring to FIGS. 13A, 13B, 14A and 14B, in one exemplary
embodiment, one or more of the installation flanges 600 are rolled
together to form sealed joints between adjacent insulated building
wrap sections. For example, the flanges 600 may provide seals
between building wrap sections 220 that are positioned above and
below one another or laterally next to one another. In the example
illustrated by FIGS. 13A, 13B, 14A and 14B, a top flange (not
shown) of a lower insulated building wrap section 1300 is attached
to the wall. A bottom flange 634 of an upper insulated building
wrap section 1310 is rolled together with the top flange 630 of the
lower insulated building wrap section 1300 to provide a seal
therebetween. Insulated building wrap 220 sections that are next to
one another can be sealed together in a similar manner. This
installation process is repeated vertically and laterally to cover
the building with the insulated building housewrap 220. In the
embodiment illustrated by FIGS. 13A and 13B, the flanges 630, 634
are rolled or folded together a single time to provide the seal. In
the embodiment illustrated by FIGS. 14A and 14B, the flanges 630,
634 are rolled or folded together a twice to provide the seal. Any
roll or fold configuration can be implemented.
[0073] Referring to FIGS. 15, 16A, 16B, 17A, and 17B, in one
exemplary embodiment, cuts 1500 are provided in the building wrap
material 222 to form fastening tabs 1502 and installation flanges
600. The fastening tabs 1502 allow the insulated building wrap to
be fixed to the wall with fasteners and/or adhesive. The
installation flanges 600 can be rolled together with other
installation flanges (or otherwise sealed together) to form sealed
joints between adjacent insulated building wrap sections. For
example, the flanges 600 may provide seals between building wrap
sections 220 that are positioned above and below one another or
laterally next to one another. In the examples illustrated by FIGS.
17A and 17B, the fastening tabs 1502 of a lower insulated building
wrap section 1700 are attached to the wall. A bottom flange 634 of
an upper insulated building wrap section 1710 is rolled together
with the top flange 630 of the lower insulated building wrap
section 1700 to provide a seal therebetween. Alternatively, the
flanges 630, 634 can be sealed together with an adhesive, by heat
bonding, etc. The installation process is repeated to cover the
building with the insulated building housewrap 220. In the
embodiment illustrated by FIG. 17A, the flanges 630, 634 are rolled
or folded together a single time to provide the seal. In the
embodiment illustrated by FIG. 17B, the flanges 630, 634 are rolled
or folded together a twice to provide the seal. Any roll or fold
configuration can be implemented.
[0074] In one exemplary embodiment, the flanges 600 are omitted.
For example, the uninsulated building wrap 220 can be installed
using fasteners that extend through the insulated building wrap 220
and/or with an adhesive. Referring to FIG. 12, in one exemplary
embodiment a fastener 1200 includes a spacer or standoff 1202. The
spacer or standoff 1202 prevents the fastener 1200 from compressing
or substantially compressing the insulated building wrap 220.
[0075] Referring to FIG. 10, in one exemplary embodiment the wall
10 includes bumpouts 1000 that have a thickness that corresponds to
the thickness of the insulated building housewrap 220. The bumpouts
1000 can take a wide variety of different forms. In one exemplary
embodiment, an exterior side of a wall 10 includes bumpouts 1000A
around a window, bumpouts around a door (not shown), and/or
bumpouts 1000B around the perimeter P of the exterior side 1020 of
the wall 10.
[0076] Referring to FIG. 11, in one exemplary embodiment the
insulated building wrap 220 is wrapped around framing members 1100
of a window rough opening 1102. A window 1104 is then installed in
the rough opening 1102 with the insulation 224 left on the building
wrap material 222. The insulated building wrap 220 may engage the
window 1104 and even be somewhat compressed by the window. As such,
the insulated building wrap 220 may act as a seal between the wall
10 and the window 1104.
[0077] Referring to FIG. 5, in one exemplary embodiment, the
insulated building wrap 220 is provided on a roll 500. The
insulated building wrap 220 may be provided on a roll 500 in a wide
variety of different configurations. In one exemplary embodiment,
the insulated building wrap 220 is provided on a roll 500 with the
building wrap material 222 outwardly disposed versus the insulation
224 being outwardly disposed. In one exemplary embodiment,
orienting the insulating building wrap 222 outward makes cutting
the insulated building wrap 220 easier. In insulated building wrap
220 is simply unrolled with the fiberglass insulation 224 up and
the building wrap material 222 downward against the ground or
floor. The fiberglass insulation 224 is then compressed and easily
cut by a sharp knife in one pass. Orienting the building wrap
material 224 outward may also reduce packaging costs, since the
smooth building wrap material 222 is primarily exposed, instead of
the fiberglass insulation 224 being primarily exposed.
[0078] As noted above, the insulated building wrap 220 may be
provided on a roll 500 in a wide variety of different
configurations. In one exemplary embodiment, the weight of the roll
500 is between 29 and 35 lbs. The roll 500 of insulated building
wrap 220 may have a horizontal dimension H of about 25 feet with
optional 6 inch flanges at each end (i.e. an insulation horizontal
dimension of 24 feet) and a vertical dimension V 5 feet, two inches
with optional 7 inch flanges at the top and bottom (i.e. and
insulation vertical dimension of 4 feet). However, any size can be
selected depending on the application.
[0079] In one exemplary embodiment, the insulated building wrap 220
has a high permeability or water vapor transfer rate (WVTR). In
some embodiments, WVTR can be at least about 5 US perms to about 29
US perms or more. In one exemplary embodiment, the WVTR can be at
least about 10 US perms to about 24 US perms or more.
[0080] In one exemplary embodiment, the thickness and/or the R
value of some portions of the installed insulation material 224 is
greater to compensate for other thinner and/or lower R value
portions of the installed insulation product. For example, the
thickness of the insulation material 224 may be selected to provide
an R value of 6 for an application that requires an average R value
of 5. This thicker insulation material compensates for low local R
values at compressed areas, such as fastening points, at corners,
etc. This allows for simpler, faster, and/or more secure
installation, because the maximum number of fasteners can be used
and it is permissible to compress part of the insulation material
224 and still provide the rated R value.
[0081] The insulated building wrap 220 can be used in a wide
variety of different applications. For example, the insulated
building wrap 220 can be used to insulate building structures like
walls, roof, fenestration, ducts, heating and cooling pipes etc.
Building structures or envelopes can be pre-built with such
insulation material incorporated into such structures.
[0082] Moreover, while this invention has been shown and described
with references to particular embodiments thereof, those skilled in
the art will understand that various other changes in form and
details may be made therein without departing from the scope of the
invention. Although only some combinations of embodiments are
claimed in the current disclosure, the current disclosure teaches
the practice of all combinations of embodiments which are
referenced by individual claims. For the purposes of disclosure, it
is understood that all such combinations of claims are hereby
taught to be practicable as per the current disclosure.
[0083] While the present invention has been illustrated by the
description of embodiments thereof, and while the embodiments have
been described in considerable detail, it is not the intention of
the applicant to restrict or in any way limit the scope of the
appended claims to such detail. Additional advantages and
modifications will readily appear to those skilled in the art.
Still further, while specifically shaped features have been shown
and described herein, other geometries can be used including
elliptical, polygonal (e.g., square, rectangular, triangular,
hexagonal, etc.) and other shapes can also be used. Therefore, the
invention, in its broader aspects, is not limited to the specific
details, the representative apparatus, and illustrative examples
shown and described. Accordingly, departures can be made from such
details without departing from the spirit or scope of the
applicant's general inventive concept.
* * * * *