Spray foam and mineral wool hybrid insulation system

Abstract

A reduced thickness and / or reduced width insulation product is provided for use in combination with spray-on foam insulation. The insulation product is configured to be inserted into standard-size spaces between adjacent wall studs to which a spray-on foam insulation has been applied. The reduced size of the insulation product is specifically designed so that the combined width and thickness of the insulation product and the spray-on foam insulation fill the entirety of the building space, but do not overfill the space.

Description

FIELD OF THE INVENTION [0001] This invention relates building insulation products generally, and more particularly to a thermal insulation material for use in combination with spray foam thermal insulation for insulating wall spaces in residential and commercial buildings. BACKGROUND OF THE INVENTION [0002] Insulation products, such as fiberglass insulation, are widely accepted for residential and light commercial construction. The insulation products are made in a variety of configurations tailored to facilitate installation in specific locations. For example, in the United States, insulation batts or rolls are often installed in wall cavities between 2×4 or ×6 studs. In many applications, this insulation technique does not reach its optimal thermal performance due to air infiltration through the cladding, sheathing and into the insulation material. [0003] One option to correct this problem is the use of a vapor-permeable water-resistant barrier, commonly referred to as “housewrap,...

AI Technical Summary

Benefits of technology

[0008] A reduced size insulation product is disclosed comprising an insulation mat having a width and a thickness. The mat can be configured for installation between a plurality of structure members, where first and second of the plurality of structure members are separated by a space width, and third and fourth of the plurality of structure members are separated by a space thickness. The insulat

Problems solved by technology

In many applications, this insulation technique does not reach its optimal thermal performance due to air infiltration through the cladding, sheathing and into the insulation material.

While this material can help prevent air infiltration and control moisture, it can also be very costly.

The problem with this technique is that the presence of a foam layer within the wall space reduces the total space available for fitting the insulation blanket or batt.

This can lead to a decrease in overall R-value of the insulation blanket or batt, and can also cause the interior walls to bulge between the studs, since the blanket / batt must be compressed in order to fit it completely within the wall space.

Additionally, for homes in which the inner sheathing is glued onto the studs, this compression can cause the sheathing to separate from the studs, which can lead to bulging, cracking, etc. of the inner wall sheathing or of the joints between sheathing panels.

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