Loose-fill insulated building structure and manufacturing method thereof

Abstract

In one aspect of the present disclosure, the insulated building structure includes a longitudinally extending cavity bounded by a first side, a second side, a rear face, and a front face, the cavity having a cross-sectional area in a plane perpendicular to the longitudinal axis of the cavity, one or more shelves extending within the cavity, each having an enclosed area in the plane that is smaller than the cross-sectional area of ​​the cavity, and loose-fill insulation disposed within the cavity, the loose-fill insulation positioned above and below each of the shelves.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 064964, filed August 13, 2020, which is incorporated herein by reference in its entirety.

[0002] FIELD OF THE INVENTION FIELD OF THE DISCLOSURE The present disclosure relates generally to systems and methods for supporting and reducing settlement of loose-fill insulation, such as blown-in insulation. [Background technology]

[0003] Insulating materials, such as fiberglass batts, rolls, blankets, or blown-in insulation, are typically used to reduce the rate of heat transfer between two areas separated by a boundary. For example, in an attic, insulating materials can be applied to the interior surface of the roof deck to slow heat transfer through the roof deck, i.e., from the exterior of the house to the attic, or vice versa. In another application, insulating materials are applied to exterior walls (e.g., between wood studs) and covered with wallboard to slow the rate of heat transfer through the exterior walls and wallboard. Insulating materials can also prevent unwanted air movement (e.g., convective drafts) and the resulting movement of moisture from one space to another.

[0004] Some of these forms of insulation, such as blown-in insulation, use loose-fill material to fill wall cavities. This loose-fill insulation can be quickly installed in walls and ceilings and can be installed into wall cavities through small holes in the wall. However, over time, the weight of the loose-fill insulation can compress the insulation and cause it to settle. This settlement can result in different amounts of insulation in different parts of the wall. In some cases, the settlement can be severe enough to create voids or gaps between the outside and inside of the cavity, where there is no insulation at all. However, even if no actual voids or gaps exist, the reduced amount of insulation in certain parts of the wall can cause undesirable heat loss through the wall.

[0005] Therefore, there is a need for improved methods and systems for supporting loose-fill insulation. Summary of the Invention

[0006] One aspect of the present disclosure is an insulated building structure, the insulated building structure comprising: a longitudinally extending cavity bounded by a first side, a second side, a rear surface, and a front surface, the cavity having a cross-sectional area in a plane perpendicular to a longitudinal axis of the cavity; one or more shelves extending into the cavity, each having an enclosed area in a plane that is less than a cross-sectional area of ​​the cavity; and loose-fill insulation disposed within the cavity, the loose-fill insulation positioned above and below each of the shelves.

[0007] In certain such embodiments, the building structure comprises: a first stud defining a first side of the cavity; a second stud laterally spaced from the first stud, the second stud defining a second side of the cavity; a rear panel extending between a rear side of the first stud and a rear side of the second stud, the rear panel defining a rear side of the cavity; a front panel extending between a front side of the first stud and a front side of the second stud, the front panel defining a front surface of the cavity; Includes.

[0008] Another aspect of the present disclosure is a method for insulating a building structure, the method comprising: To provide a building structure, the building structure comprising: a longitudinally extending cavity bounded by a first side, a second side, a rear surface, and a front surface, the cavity having a cross-sectional area in a plane perpendicular to a longitudinal axis of the cavity; one or more shelves extending into the cavity, each having an enclosed area in a plane that is less than a cross-sectional area of ​​the cavity; and placing loose-fill insulation within the cavity so as to be positioned above and below each of the shelves.

[0009] Further aspects of the present disclosure will become apparent from the disclosure herein. [Brief explanation of the drawings]

[0010] The accompanying drawings are included to provide a further understanding of the methods and devices of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings are not necessarily to scale, and sizes of various elements may be distorted for clarity. The drawings illustrate one or more embodiments of the present disclosure and, together with the description, serve to explain the principles and operation of the present disclosure. [Figure 1] 1 is a schematic partial front view of a prior art insulating wall. [Figure 2] 1 is a schematic cross-sectional view of an insulating wall according to one embodiment of the present disclosure. [Figure 3] 1 is a schematic cross-sectional view of an insulating wall according to an alternative embodiment of the present disclosure. [Figure 4] FIG. 10 is a schematic cross-sectional view of an insulating wall according to another alternative embodiment of the present disclosure. [Figure 5] 1 is a schematic cross-sectional view of a method for insulating a wall according to one embodiment of the present disclosure. [Figure 6]FIG. 10 is a schematic cross-sectional view of a wall having a shelf for supporting insulation according to another alternative embodiment of the present disclosure. [Figure 7] FIG. 10 is a schematic cross-sectional view of a wall having a shelf for supporting insulation according to another alternative embodiment of the present disclosure. [Figure 8] FIG. 10 is a schematic cross-sectional view of a wall having a shelf for supporting insulation according to another alternative embodiment of the present disclosure. [Figure 9] 1 is a graph of apparent thermal conductivity versus density for several insulation materials used as building insulation. DETAILED DESCRIPTION OF THE INVENTION

[0011] As noted above, the present inventors have noted certain shortcomings in existing methods for insulating building structures such as walls and sloped ceilings and roofs.

[0012] Thus, one aspect of the present disclosure is an insulated building structure. Such structures often take the form of walls, as described with respect to the following figures, although those skilled in the art will understand that other uses, such as sloped ceilings or roofs, are possible. Indeed, the methods and structures described herein can be used with cavity structures having portions extending in any desired plane, e.g., vertical, horizontal, or inclined directions. The insulated building structure includes a longitudinally extending cavity bounded by a first side, a second side, a rear face, and a front face, the cavity having a cross-sectional area in a plane perpendicular to the longitudinal axis of the cavity, and one or more shelves extending within the cavity, each shelf having an enclosed area in the plane that is smaller than the cross-sectional area of ​​the cavity. Loose-fill insulation is positioned within the cavity both above and below each shelf.

[0013] In one typical construction, the insulated building structure includes a first stud defining a first side of a cavity; a second stud laterally spaced from the first stud and defining a second side of the cavity; a rear panel extending between rear sides of the first and second studs and defining the rear side of the cavity; and a front panel extending between front sides of the first and second studs and defining the front side of the cavity, the two studs and two panels defining the cavity therebetween. The longitudinal axis of the first stud defines the longitudinal axis of the cavity. One or more shelves disposed within the cavity are positioned between the first and second studs. As used herein, the term "stud" encompasses other substantially straight frame members, including joists.

[0014] Another aspect of the present disclosure is a method of insulating a building cavity, for example, a wall cavity, comprising providing a structure as described herein (i.e., including a cavity having one or more shelves extending therethrough) and applying loose-fill insulation within the cavity such that each of the one or more shelves has insulation disposed thereon and therebelow.

[0015] Compared to other systems for insulating building cavities with loose-fill insulation, the disclosed systems and methods may be advantageous in that, in certain embodiments, one or more shelves support at least a portion of the weight of the insulation, so that the weight supported by the shelves does not act on the insulation positioned below the shelves, thereby reducing compression and settlement of the insulation over time.

[0016] Compared to other systems for insulating building cavities with loose-fill insulation, the disclosed systems and methods can provide the advantage that, in certain embodiments, one or more shelves provide additional surface area to support the weight of the loose-fill insulation, thus allowing for more even distribution of the insulation throughout the structure. The additional surface area provides more opportunity for friction between the insulation fibers and the shelves and other cavity surfaces, and such friction reduces compression or settlement of the insulation material over time.

[0017] Insulation settlement can result from vibrations that a cavity may be subjected to at any time during its useful life. Settlement can occur during the process of installing insulation into the cavity, after the cavity is subjected to an impact (due to an earthquake or other vibration event), or from transportation of a pre-filled cavity from the manufacturing site to the end-use site. Even changing the orientation of a cavity or cavity element, which may be filled while assembled face down in a manufacturing environment, to a vertical position for assembly into a larger structure can cause settlement.

[0018] It should be noted that the size and arrangement of the one or more shelves can be selected by one skilled in the art to allow for spray-on insulation during installation. In certain embodiments, each of the shelves has a first end adjacent to a first surface defining the cavity and a second end distal to the first surface and spaced apart from a second surface defining the cavity, the second surface being opposite the first surface. For example, in certain embodiments as otherwise described herein, one or more of the shelves have a first end adjacent to a first side of the cavity and a second end distal to the first side of the cavity and spaced apart from a second side of the cavity. In certain embodiments as otherwise described herein, one or more of the shelves have a first end adjacent to a second side of the cavity and a second end distal to the second side of the cavity and spaced apart from the first side of the cavity. In certain embodiments as otherwise described herein, one or more of the shelves have a first end adjacent a front surface of the cavity and a second end distal to the front surface of the cavity and spaced apart from the rear surface of the cavity. In certain embodiments as otherwise described herein, one or more of the shelves have a first end adjacent a rear surface of the cavity and a second end distal to the rear surface of the cavity and spaced apart from the front surface of the cavity.

[0019] In certain embodiments as otherwise described herein, one or more of the shelves (e.g., each of the shelves) is angled relative to the plane such that its top major surface is higher at its second end than at its first end. The angle of the top major surface of the shelf relative to the plane can be, for example, up to 45 degrees, e.g., up to 30 degrees, or in a range of 5 to 45 degrees, or 15 to 45 degrees, or 5 to 30 degrees.

[0020] Often, multiple shelves are present within the cavity, for example, at least four shelves, at least six shelves, or even at least twelve shelves.

[0021] Referring now to the drawings, FIG. 1 is a front view of a portion of an example of a conventional wall 10 having loose-fill insulation 20 disposed within a cavity. Wall 10 includes studs 12A, 12B, and 12C, each having a height H. In the embodiment of FIG. 1, top plate 11 extends along the upper ends of studs 12A, 12B, and 12C. Base or bottom plate 13 extends along the lower ends of studs 12A, 12B, and 12C. Wall 10 further includes a rear panel 17 extending between the rear sides of studs 12A, 12B, and 12C. Wall 10 also includes a front panel (not shown) extending along the front sides of studs 12A, 12B, and 12C. The studs and panels define cavities 14A (between studs 12A and 12B) and 14B (between studs 12B and 12C), which are also vertically defined by plates.

[0022] Those skilled in the art will understand that the materials of the structures described herein can vary. The studs can be formed, for example, of wood or metal. The front and rear panels can be formed of the same or different materials. Each can be formed from a material that serves as the exterior surface of the structure, such as wallboard, lath and stucco, or sheathing (e.g., gypsum board, oriented strand board (OSB), fiberboard, plywood, foam board, brick, masonry, monolithic block, stone, or other common building materials). However, those skilled in the art will understand that insulation is often blown into building cavities before the cavities are closed with the final facing material. In such cases, a sheet of flexible material, such as fabric, mesh, or plastic sheeting, serves as the front panel that closes the cavity for the purpose of blowing in loose-fill insulation. Openings can be provided in the sheet to allow access to the tube cavities for blowing in the insulation. This sheet can then be covered with a facing material, such as wallboard, lath and stucco, or sheathing. In certain embodiments as otherwise described herein, the rear surface defining the cavity is provided by wallboard, lath and plaster, or cladding, and the front panel defining the cavity is provided by a sheet of flexible material such as fabric, mesh, or plastic sheeting.

[0023] In the embodiment of FIG. 1 , cavities 14A, 14B have the same height H as studs 12A, 12B, and 12C. Cavities 14A, 14B each have a width W equal to the distance between two studs. For example, if studs 12A, 12B, and 12C are standard 2× studs spaced according to a 16-inch on-center pattern, the width W is approximately 14.5 inches. Similarly, if studs 12A, 12B, and 12C are standard 2× studs spaced according to a 24-inch on-center pattern, the width W is approximately 22.5 inches. However, these are merely examples, and one of ordinary skill in the art will understand that other widths W are contemplated herein. Cavities 14A, 14B have a depth D approximately equal to the depth of studs 12A, 12B, and 12C. For example, the depth D is about 3.5 inches for 2x4 studs, about 5.5 inches for 2x6 studs, and about 7.25 inches for 2x8 studs. As noted above, other depths are contemplated herein.

[0024] Thus, cavities 14A, 14B each have a cross-sectional area of ​​W×D in a plane perpendicular to the longitudinal axis L of first stud 12A, e.g., the horizontal plane of the vertical wall.

[0025] As shown, cavities 14A, 14B each contain loose-fill insulation 20. However, the loose-fill insulation 20 is compressed and stable, leaving a void 21 near the top of cavities 14A, 14B.

[0026] Referring to FIG. 2, a system 100 for insulating a building cavity is shown. System 100 includes studs 112A, 112B, 112C, a top plate 111, and a bottom plate 113 substantially similar to those shown in FIG. 1 and described above. System 100 further includes a rear panel 117 and a front panel 116 (see FIG. 5) substantially similar to those described above. Studs 112A, 112B, 112C, panels, and plates 111, 113 define cavities 114A, 114B. Cavities 114A, 114B each have a height H, a width W, and a depth D (see FIG. 1). Thus, each cavity has a cross-sectional area, in a plane perpendicular to the longitudinal axis L of first stud 112A, equal to W×D.

[0027] In the embodiment shown herein, the system 100 forms a vertical wall 101, and therefore the plane is a horizontal plane. However, it should be understood that the described system 100 can be used in ceilings and roofs, such as sloped ceilings, where the studs 112A, 112B, and 112C are ceiling beams. In certain embodiments as otherwise described herein, the cavity extends longitudinally (e.g., the studs are placed) at an angle of 60 degrees or less from the vertical, e.g., 45 degrees or less from the vertical. In certain embodiments as otherwise described herein, the cavity extends longitudinally (e.g., the studs are placed) at an angle of 30 degrees or less from the vertical, e.g., 15 degrees or less from the vertical. In certain embodiments, the cavity extends longitudinally (e.g., the studs are placed) at an angle of 5 degrees or less from the vertical. The systems described herein are particularly advantageous for substantially vertically extending cavities, since settlement of loose-fill insulation is more problematic in such cavities.

[0028] 2 further includes a plurality of shelves 130A-C disposed within each cavity 114A, 114B. In this embodiment, each of the shelves 130A-C is substantially similar. Shelf 130A is described in more detail below as an illustrative example.

[0029] The shelf 130A in the embodiment of FIG. 2 includes a first end 131 and a second end 132. The first end is adjacent a surface 118 that defines one edge of the cavity 114A. In the illustrated embodiment, the surface 118 adjacent the first end 131 of the shelf 130A is a first stud 112A. In some configurations, the first end 131 is coupled to the stud 112A. The second end 132 is opposite the first end 131 and distal from the surface adjacent to it (e.g., the first stud 112A). In a preferred configuration, the shelf is angled relative to a plane perpendicular to the axis L such that the second end 132 of the shelf 130A is higher than the first end 131. Thus, the weight of the first portion of insulation 120A located above the first shelf 130A acts in part to hold the portion of insulation 120A toward the first stud 112A.

[0030] Shelf 130A has a depth less than or equal to D. As shown, the shelf has a width W2 that is less than the width W of cavity 114A. Thus, shelf 130A has an enclosed area in a plane perpendicular to L that is less than W×D.

[0031] A second end 132 of shelf 130A is spaced apart from face 119 opposite face 118. Proximate second end 132 of shelf 130A is opening 133A, through which insulation material can flow from above shelf 130A to below shelf 130A. During operation, insulation material is blown into cavity 120A from a single point. The point of installation may be a hole in the wall or a hole in the film or blanket defining the front of the cavity. Alternatively, the point of installation may be the top of the wall through top plate 111. During installation, insulation material passes through openings 133A, 133B, and 133C to fill sections 115A, 115B, and 115C of cavity 114A. After installation, the insulation material is partially divided into sections 120A, 120B, 120C, and 120D by shelves 130A, 130B, and 130C. The shelves 130A, 130B, 130C partially support the weight of the sections of insulation 120A, 120B, 120C located above the shelves, thereby reducing the amount of pressure acting to compress the insulation located below each shelf.

[0032] 3 illustrates system 200 with an alternative configuration of shelves 230A, 230B, 230C. Odd shelves 230A, 230C are substantially similar to corresponding shelves 130A, 130C shown in FIG. 2 and described above. Even shelf 230B is mirrored compared to corresponding shelf 130A shown above.

[0033] System 200 includes a first shelf 230A having a first end 231 coupled to a first stud 112A. The first shelf 230A extends into cavity 114A toward a second stud 112B. An opening 233A exists between a second end 232 of first shelf 230A and the second stud 112B.

[0034] The system further includes a second shelf 230B having a first end 231 coupled to the second stud 112B. The second shelf 230B extends into the cavity 114A toward the first stud 112A. An opening 233B exists between a second end 232 of the second shelf 230B and the first stud 112A.

[0035] As shown, first opening 233A and second opening 233B are laterally offset from one another. Thus, the insulation directly above first opening 233A is at least partially supported by second shelf 230B. Similarly, the insulation directly above second opening 233B is at least partially supported by third shelf 230B. By offsetting openings 233A-C in this manner, the amount of force acting to compress the insulation along openings 233A-C is reduced.

[0036] The illustrated example shows three shelves 230A-C in each cavity 114A, 114B, although it is understood that the embodiment is not limited to three shelves. System 200 includes two or more shelves spaced apart and staggered along the height H of cavity 114A.

[0037] FIG. 4 illustrates system 300 with an alternative configuration of shelves 330A-330F. As shown, the shelves are arranged in pairs 330A-B, 330C-D, and 330E-F. Each pair of shelves is substantially the same height as the other and is located at a common location along height H of cavity 114A. In this embodiment, the shelf pairs are located such that their angles are mirror images of each other. However, one skilled in the art will appreciate that other configurations are possible. Shelves 330A-F divide the insulation into zones 320A-D.

[0038] Shelf 330A has a first end 331 adjacent first surface 118. In the illustrated embodiment, first surface 118 is first stud 112A. Shelf 330A has a second end 332 distal from first surface 118. Second shelf 330B has a first end 331 adjacent second surface 119 opposite first surface 118. In the illustrated embodiment, second surface 119 is second stud 112B. Second shelf 330B has a second end 332 distal from second surface 119. The second ends 332 of the two shelves 330A-B are spaced apart from one another to define an opening 333A therebetween. As discussed above, opening 333A allows insulation material to flow between sections 115A, 115B of cavity 114A during installation.

[0039] The remaining pairs 330C-D, 330E-F are substantially similar to pairs 330A-B described above. In the illustrated form, the openings 333A-C are aligned. However, it is understood that the lengths of the shelves 330A-F can be adjusted to offset the openings for the reasons described above.

[0040] As shown, shelf 330A has a width W3 that is shorter than shelf 130A of the embodiment of Figure 2. By shortening shelf 330A in this manner, the amount of torque applied to the joint between first end 331 of shelf 330A and first surface 118 is reduced. Torque can be further reduced by attaching second ends 332 of pair of shelves 330A-B with plates located at their front and / or rear.

[0041] The above embodiments illustrate systems in which the shelf is adjacent to the first stud 112A and spaced apart from the second stud 112B, thus leaving an opening through which insulation can flow between the shelf and the second stud 112B. However, a similar effect can be achieved by having a shelf extending the full width of the cavity 114A adjacent to one of the rear and front panels and spaced apart from the other of the rear and front panels. Such a configuration is shown in FIG. 5 and described below.

[0042] FIG. 5 illustrates system 400. FIG. 5 is a cross-sectional view of cavity 114A, showing top plate 111, bottom plate 113, front panel 116, and rear panel 117. It is understood that cavity 114A is further defined by first stud 112A and second stud 112B, as shown in the previous embodiment. Front panel 116 is formed from a flexible sheet, such as a blanket, for securing insulation 420 in place during installation. Once the wall is completed, front panel 116 is replaced or covered by a solid wall material, such as sheathing, wallboard, or lath and stucco. Alternatively, front panel 116 may remain in place and be permanently covered by an additional layer of solid wall material, such as sheathing, wallboard, or lath and stucco.

[0043] The system 400 includes a plurality of shelves 430A-C disposed within the cavity 114A. The shelves 430A-C are substantially similar. The following description will be given taking the first shelf 430A as an example.

[0044] Shelf 430A has a first end 431 adjacent first surface 418 that defines cavity 114A. In the illustrated form, first surface 418 is rear panel 117. Shelf 430A has a second end 432 distal from first surface 418. Shelf 430A is angled relative to a plane perpendicular to axis L such that second end 432 is higher than first end 431.

[0045] The shelf 430A extends across the width W of the cavity 114A. The shelf 430A is coupled to the first stud 112A and the second stud 112B. However, the shelf 430A has a depth D2 that is less than the depth D of the cavity 114A. Thus, the shelf 430A has an enclosed area in a plane perpendicular to the axis L that is less than W×D.

[0046] The second end 432 of the shelf 430A is spaced from the front panel 116, defining an opening therebetween. FIG. 5 illustrates the installation process for the insulation 420. As shown, the hose 401 is positioned within the opening 402 in the front panel 116. The end of the hose 401 is within the section 115C of the cavity 114A between the second shelf 430B and the third shelf 430C. The insulation 420 is blown from the hose 401 into the cavity 114A. The insulation 420 flows through the openings 433A-C between the shelves 430A-C and the front panel 116, filling each section 115A-D of the cavity 114A. As with the previous embodiment, each shelf 430A-C at least partially supports the weight of the sections 420A-C of insulation positioned thereon.

[0047] While shelves 430A-430C are each adjacent the same face 418, it is understood that other embodiments similar to those described above are also contemplated herein. For example, even-numbered shelf 430B can be mirrored to be adjacent the opposite face 419, staggering openings 433A-C as in FIG. 3. Alternatively, shelves 430A-C can be arranged in pairs as shown in FIG. 4.

[0048] In other embodiments, the shelf can protrude from the rear panel without contacting the studs. In such cases, the shelf can be attached to the rear panel and extend forward toward the front panel. In certain such embodiments, the shelf extends a distance less than W to serve to divide the cavity into zones where insulation can accumulate, while still having areas where insulation can be distributed to other zones within the cavity.

[0049] For example, in various embodiments shown in Figures 6-8, the shelves are not connected to any of the studs 112A-C. Referring first to Figure 6, system 500 includes multiple shelves 530A-D. Shelves 530A-D are coupled to rear panel 117.

[0050] Shelf 530A is positioned between studs 112A and 112B. Shelf 530A is spaced apart from both studs 112A and 112B. Shelf 530B is spaced apart horizontally from shelf 530A and is located between studs 112A and 112B. Shelf 530B is spaced apart from both studs 112A and 112B. Cavity areas 115B and 115C are therefore connected by three channels 533A-C to facilitate the installation of loose-fill insulation (not shown), as described above. As shown, shelves 530A and 530B are horizontal. However, the shelves could also be angled, such as shelves 530C and 530D.

[0051] Shelves 530C-D are positioned between studs 112B and 112C. Shelves 530C-D are horizontally spaced apart from one another and each horizontally spaced apart from both studs 112B and 112C. Thus, shelves 530C-D similarly define three channels through which insulation material can flow.

[0052] 7, system 600 includes a plurality of shelves 630A-C having an arcuate shape. Each shelf 630A-C is spaced apart from all of studs 112A-C and instead is coupled to rear panel 117.

[0053] In some embodiments, shelf 630A has an upwardly facing arc shape. The upwardly facing arc shape is configured to support the insulation when system 600 is in a vertical orientation. In alternative embodiments, shelves 630B-C have different orientations, such as one facing up and the other facing down. The different shelf orientations provide support for the insulation when system 600 is rotated or inverted, such as in prefabricated construction applications as described below.

[0054] In some configurations, shelves 630B-C are arranged in interlocking pairs. A first end of shelf 630B interlocks with a second end of shelf 630C to form a single continuous shelf. In alternative configurations, additional interlocking shelves can be connected to either end of shelf 630B or 630C to form a longer continuous shelf.

[0055] 8 shows a system 700 with additional alternative shelf configurations. System 700 includes a stepped shelf 730A and a V-shaped shelf 730B. Shelves 730A-730B are spaced apart from studs 112A-C. Shelves 730A-730B are coupled to rear panel 117.

[0056] The tiered shelf 730A has a first horizontal portion 771 and a second horizontal portion 772 connected by a vertical portion 773. However, it is understood that the tiered shelf 730A can be installed in alternative orientations such that the parallel sections 771 and 772 are perpendicular or oblique to the vertical axis.

[0057] The V-shaped shelf 730B is formed from two sections 775 and 776 that are angled relative to one another. Although each of the illustrated shelves 730B is vertical, it is understood that one or more of the shelves 730B can be rotated to provide support for the insulation in different orientations.

[0058] In each of the above embodiments, the shelves are represented by solid lines. However, shelves formed from non-solid materials are contemplated herein. For example, any of the shelves described above can be formed from mesh, sheet metal, rods, pins, or other materials. In some forms, the shelves are formed from wood, metal, or plastic with one or more openings therethrough. The openings or apertures in the non-solid shelves allow airflow through the shelves during the air-filling operation. This additional airflow aids in the even distribution of insulation throughout the cavity.

[0059] Based on the disclosure herein, one skilled in the art can select the size and pattern of the shelves to reduce the amount of settlement of the insulation while still allowing the loose-fill insulation to substantially fill the cavity during the blow-in installation process.

[0060] Each shelf has an obstructed area in a plane perpendicular to the longitudinal direction of the cavity. The obstructed area is the cross-sectional area of ​​the cavity obstructed by the shelf. As noted above, the obstructed area is less than the cross-sectional area of ​​the cavity (i.e., in a plane perpendicular to the longitudinal direction of the cavity). In certain embodiments as otherwise described herein, each shelf has an obstructed area that is 90% or less of the cross-sectional area of ​​the cavity. In certain desirable embodiments, each shelf has an obstructed area that is 80% or less, 70% or less, 60% or less, or even 50% or less of the cross-sectional area of ​​the cavity. In certain embodiments as otherwise described herein, each shelf has an obstructed area that is at least 5% of the cross-sectional area of ​​the cavity. In certain desirable embodiments, each shelf has an obstructed area that is at least 10%, at least 15%, or even at least 20% of the cross-sectional area of ​​the cavity. For example, in various embodiments, each shelf has an enclosed area ranging from 5 to 90% of the cross-sectional area of ​​the cavity, e.g., 5 to 80%, or 5 to 70%, or 5 to 60%, or 5 to 50%, or 10 to 90%, or 10 to 80%, or 10 to 70%, or 10 to 60%, or 10 to 50%, or 15 to 90%, or 15 to 80%, or 15 to 70%, or 15 to 60%, or 15 to 50%, or 15 to 90%, or 20 to 80%, or 20 to 70%, or 20 to 60%, or 20 to 50%. One skilled in the art can select the size of the shelves, along with the number of shelves, to provide a configuration that allows insulation to be blown through the shelves during insulation, yet provides sufficient support for the insulation after installation.

[0061] In certain embodiments, each shelf has a depth that is at least 25% of the depth of the cavity (at the location where it is disposed). For example, in certain embodiments, each shelf has a depth that is at least 40%, e.g., at least 50%, or at least 60% of the depth of the cavity. Where a shelf does not extend across the entire width of the cavity (e.g., extending across no more than 70%, no more than 60%, or no more than 50% of the width of the cavity), in some embodiments the shelf may extend across the entire depth of the cavity. In certain embodiments where the shelf extends across a significant proportion of the overall width of the cavity (e.g., at least 50%, at least 60%, or at least 70% of the width of the cavity), the shelf extends across no more than 70% of the depth of the cavity, e.g., no more than 60%, no more than 50%, or no more than 40% of the depth of the cavity. In certain embodiments as otherwise described herein, each shelf has a depth in the range of 25-100% of the depth of the cavity, e.g., 25-70%, or 25-60%, or 25-50%, or 40-100%, or 40-70%, or 40-60%, or 50-100%, or 50-70%, or 60-100% of the depth of the cavity.

[0062] In certain embodiments, each shelf has a width that is at least 20% of the width of the cavity (at the location where it is located). For example, in certain embodiments, each shelf has a width that is at least 30%, e.g., at least 40%, or at least 50% of the width of the cavity. Where a shelf does not extend across the entire depth of the cavity (e.g., extending across no more than 70%, no more than 60%, or no more than 50% of the depth of the cavity), in some embodiments, it can extend across the entire width of the cavity. In certain embodiments where a shelf extends across a significant proportion of the total depth of the cavity (e.g., at least 50%, at least 60%, or at least 70% of the depth of the cavity), the shelf extends across no more than 70% of the width of the cavity, e.g., no more than 60%, no more than 50%, or no more than 40% of the width of the cavity. In certain embodiments as otherwise described herein, each shelf has a width in the range of 25-100% of the depth of the cavity, e.g., 25-70%, or 25-60%, or 25-50%, or 40-100%, or 40-70%, or 40-60%, or 50-100%, or 50-70%, or 60-100% of the width of the cavity.

[0063] In certain embodiments, the shelves are provided in the cavity such that the average insulation height in the longitudinal direction (e.g., parallel to the first stud), i.e., taken as the average insulation height (between the shelves, or between the shelf and the top of the insulation, or between the bottom of the cavity and the shelf), is 4 feet or less. That is, averaged across the cavity, the height of the body of insulation between support surfaces is 4 feet or less. For example, in certain embodiments described elsewhere herein, the average insulation height is 3 feet or less, e.g., 2 feet or less.

[0064] In certain embodiments, the shelves are positioned within the cavity such that the maximum insulation height possible in the longitudinal direction within a fully filled cavity is 4 feet or less. For example, in certain embodiments as otherwise described herein, the maximum insulation height possible in the longitudinal direction is 3 feet or less, e.g., 2 feet or less.

[0065] The shelves can be arranged in a variety of ways by one skilled in the art based on the disclosure herein. For example, in certain embodiments, the shelves extend in alternating directions, such as alternating between extending from a first stud and extending from a second stud, or alternating between extending from the front panel and extending from the rear panel. However, in other embodiments, the shelves extend in the same direction throughout the cavity, such as from the rear panel.

[0066] The shelves can be made from a variety of materials, such as plastic, wood, fabric (e.g., supported or rigid), cardboard, plaster, or metal. They can be attached to the studs and / or panels in a variety of ways, such as with nails, staples, screws, brackets, pressure-sensitive adhesive, or glue.

[0067] The present disclosure also provides a method for insulating a building structure, such as a wall, ceiling, or roof, as described above. The method includes providing a building structure of any configuration as described above, the building structure including, for example, a first stud, a second stud laterally spaced from the first stud, a rear panel extending between a rear side of the first stud and a rear side of the second stud, a front panel extending between a front side of the first stud and a front side of the second stud, the first stud, the second stud, the rear panel, and the front panel defining a cavity therebetween having a first cross-sectional area in a plane perpendicular to the longitudinal axis of the first stud, and a first shelf disposed in the cavity, the first shelf having an enclosed area smaller than the first cross-sectional area. The method further includes disposing loose-fill insulation within the cavity so as to be positioned above and below each of the shelves. As mentioned above, multiple shelves can be placed within the cavity to improve support for the insulation while still allowing the insulation to flow around the shelves during the blowing process, with loose-fill insulation placed above and below each shelf.

[0068] The building structure itself (i.e., not including the insulation) can be as described in any of the various embodiments above.

[0069] The methods and structures of the present disclosure may be useful in a variety of construction situations. For example, a building structure including the shelves described herein may be provided as part of a building and then insulated by blowing in insulation.

[0070] The inventors have also determined that the methods and structures described herein can be particularly useful in the manufacture of prefabricated building structures. Prefabricated structures are formed from wall and / or ceiling sections that are made off-site, such as in a factory, and then installed on-site as part of a building. Thus, in certain embodiments as described elsewhere herein, the insulated building structure is prefabricated and not installed as part of a building. Such an insulated building structure can be transported to a building site and then installed as part of a building. In particular, during manufacturing, transportation, and installation, prefabricated walls may be turned over, vibrated, and otherwise moved. Advantageously, the prefabricated building structure can be transported horizontally. In typical prefabricated wall or ceiling sections, this can cause insulation to settle. The shelves reduce the amount of insulation settling as a result of this movement. In the methods and structures described herein, the shelves can help prevent insulation from settling during manufacturing, transportation, and installation.

[0071] One method of manufacturing the structure involves assembling a wall from a plurality of studs, top plates, bottom plates, and interior and exterior cladding, with one or more shelves, such as those shown in Figures 2-8 above, positioned within the wall cavity. The wall cavity is also filled with loose-fill insulation.

[0072] In a method for producing a prefabricated building structure, the insulation can be blown into an already-prepared cavity as described above, but in other embodiments, the insulation is distributed into the cavity before one of the rear and front panels closes the cavity. This allows the insulation to be more easily deposited relatively evenly throughout the cavity space, and the front or rear panel (e.g., sheathing) can then be installed to close the cavity. One advantage of such installation is that no holes need to be drilled in the fabric or sheathing material. In certain embodiments, the building structure is positioned so that when the loose-fill insulation is placed therein, its longitudinal extension is within 15 degrees of horizontal, for example, within 5 degrees of horizontal.

[0073] Various loose-fill insulation materials can be used in implementing the methods and structures described herein. For example, known insulation materials include stone wool, rock wool, fiberglass, polyester, cellulose, polystyrene pellets, vermiculite, and cotton. Such materials can be provided as bound materials or without binders, and desirably are free of adhesives, liquids, and moisture that promote agglomeration and cohesion of the fibers or clumps of the material. The loose-fill material can be a product made specifically for installation within a cavity, such as Insulsafe® brand insulation (available from Certain Teed LLC), or it can be insulation originally in batt or blanket form that has been chopped or diced to reduce particle size for transport into the cavity.

[0074] In certain embodiments described elsewhere herein, the insulation used to insulate the structure is one that achieves a k value of 0.31 or less at densities of 0.37 lbs / cubic foot or greater, a k value of 0.29 or less at densities of 0.6 lbs / cubic foot or greater, a k value of 0.27 or less at densities of 0.7 lbs / cubic foot or greater, a k value of 0.26 or less at densities of 0.8 lbs / cubic foot or greater, a k value of 0.25 or less at densities of 1.0 lbs / cubic foot or greater, a k value of 0.24 or less at densities of 1.2 lbs / cubic foot or greater, and a k value of 0.23 or less at densities of 1.3 lbs / cubic foot or greater.

[0075] Those skilled in the art can use any convenient technique for placing loose-fill insulation. Such insulation is typically blown in through a pipe, for example, through an opening in the front panel. It should be noted that because loose-fill insulation can pass along a shelf during insulation, the insulation can be introduced into the cavity in fewer locations (e.g., through fewer openings in the front panel). For example, in certain embodiments, the insulation is introduced into the cavity in three or fewer locations, e.g., three locations, two locations, or only one location. In a contrasting example, the insulation may be manually or mechanically deposited into a cavity positioned horizontally relative to a standard plane, such as in a factory to create a prefabricated building structure, so care can be taken to ensure that the insulation is installed at a specific and uniform density within the cavity space and along the surface of the shelf. The presence of the shelf can help prevent settling of the insulation due to movement, shipping, and assembly into the building, as well as settling over time. Of course, one skilled in the art will appreciate that other techniques can be used to place the insulating material within the cavity as described herein.

[0076] The inventors have noted that settlement of insulation can significantly affect the overall thermal insulation value of a building structure. In extreme cases, settlement can result in voids near the top of a wall, and if a portion of the wall cavity is devoid of insulation, that portion of the wall may be able to efficiently transfer heat therethrough. However, even if no voids form, settlement can result in variations in insulation density throughout the wall cavity. Figure 9 is a graph of apparent thermal conductivity versus density for several insulation materials used in building insulation. The graph shows that differences in insulation density can dramatically affect the insulating quality of the insulation, especially at low insulation densities. For example, reducing the density of rock wool or fiberglass / fiberglass insulation from 2 pounds per cubic foot to 1 pound per cubic foot can increase the apparent thermal conductivity by more than 20%. These areas of higher thermal conductivity form thermal channels through which heat can pass more quickly through the wall, lowering the overall U-value of the structure. To protect against this, insulation is traditionally installed at a higher density than nominally required for the desired insulation value, allowing the insulation value to remain within specification even after some settlement. The use of shelves as described herein can help reduce the variability in insulation density, and therefore can allow for the use of less insulation material to achieve the desired insulation value.

[0077] Referring to the graph of FIG. 9 , target insulation density is traditionally selected along the flat portion of the curve for a given material, so that a decrease in density at a particular point due to settlement does not result in a significant increase in thermal conductivity (typically more than 2.4 lbs / ft3 for fiberglass insulation and more than 4 lbs / ft3 for rock wool). Therefore, traditional insulation is dispensed at a somewhat higher density than strictly necessary to ensure that the desired level of insulation is maintained even when density in certain areas of the structure is reduced due to settlement. By using shelves as described herein to support the insulation within the cavity, certain embodiments can reduce or eliminate the need for increased density. Therefore, in certain embodiments as otherwise described herein, equivalent thermal performance densities can be selected, such as 1.6 lbs / ft3 for fiberglass insulation (a 30% reduction compared to conventional methods) or 3 lbs / ft3 for rock wool insulation (a 25% reduction compared to conventional methods), to provide approximately equivalent thermal conductivity or k values. Such densities are near the edge of a drop in insulation value with respect to density reduction, but the density reduction is much less likely as a result of the presence of the shelf. As will be appreciated by those skilled in the art, at similar k values ​​(which are the inverse of R-value), a wall section can meet thermal R-value requirements with significantly less mass of installed insulation material.

[0078] In a typical wall assembly, it is desirable to achieve either R-11, R-13, R-14, or R-15 in the space of a standard 2x4 wall stud cavity (real depth D of 3.5 inches), R-19, R-21, or R24 ​​in the space of a standard 2x6 wall stud cavity (real depth D of 5.5 inches), or R-29 or R-31 in the space of a standard 2x8 wall stud cavity (real depth D of 7.25 inches).

[0079] For stud cavity 2x4 walls, R-14 walls require a k value of 0.25, while R-15 walls require a k value of 0.24. The ability to achieve such k values, closer to the target design density of 1.0 lbs / ft3 for fiberglass insulation compared to the more typical 1.6 to 2.4 lbs / ft3 required to ensure settlement does not significantly affect thermal conductivity, can reduce material usage by anywhere from 30% to 58%. To achieve the higher k values ​​of 0.27 required for R-13 walls and 0.32 required for R-11, the respective densities can be reduced to 0.7 lbs / ft3 for R-13 and 0.37 lbs / ft3 for R-11. These are much lower than the typical densities required for conventional cavity wall installations of loose-fill fiberglass material (which often estimate a minimum density of 1.2 lbs / ft3 for 2x4 construction).

[0080] This effect can be even more pronounced for thicker wall sections. For an R-19 wall with a 2x6 stud cavity (5.5-inch depth D), a k-value of 0.29 is thermally required. However, if a minimum density of 1.6 lbs / ft3 was required to provide some settlement, such a wall would be over-insulated because only 0.6 lbs / ft3 would be required to achieve the 0.29 k-value. The ability to achieve this thermal value through the use of shelving as described herein results in a 62% savings in material used and still achieve the same overall R-value performance. Similarly, a density of 0.8 lbs / ft3 could provide the 0.26 k-value required for an R-21 wall with a 2x6 construction (5.5-inch depth D). Finally, an R-24 wall in 2x6 construction (5.5 inch depth D) requires a k value of 0.23 to achieve its thermal rating, which can now be achieved at a density of 1.3 lbs / ft3 (while still achieving a savings of over 18%) rather than the typically specified 1.6 lbs / ft3 or higher.

[0081] For a 2x8 wall (7.25 inch depth D), a k-value of 0.25 is required to achieve R-29. This is traditionally a recommended installation density of 1.2 pounds per cubic foot, but the desired k-value can be achieved at a 20% lower density of 1.0 pounds per cubic foot by instead using shelves to prevent settlement as described herein. For an R-31 wall (k-value of 0.24), using shelves as described herein can provide a density of 1.2 pounds per cubic foot (a 25% savings in material) compared to the traditional density of 1.6 pounds per cubic foot.

[0082] Because loose-fill insulation is typically sold in bags or compressed bales of material, this reduction in density means that fewer bags of insulation are needed to insulate the same space to the same R-value required by applicable local codes. This reduction means more efficient use of natural resources, fewer bags of insulation that installers must lift and handle, and fewer bags of insulation that need to be delivered to a job site for installation—all resulting in economic, environmental, and ergonomic improvements.

[0083] Additional aspects of the present disclosure are provided by the embodiments listed below, which can be combined in any number and in any manner that is not technically or logically inconsistent.

[0084] Embodiment 1. An insulated building structure, a longitudinally extending cavity bounded by a first side, a second side, a rear surface, and a front surface, the cavity having a cross-sectional area in a plane perpendicular to a longitudinal axis of the cavity; one or more shelves extending into the cavity, each having an enclosed area in a plane that is less than a cross-sectional area of ​​the cavity; loose-fill insulation disposed within the cavity, the loose-fill insulation positioned above and below each of the shelves; An insulated building structure comprising:

[0085] Embodiment 2. The building structure is a first stud defining a first side of the cavity; a second stud laterally spaced from the first stud, the second stud defining a second side of the cavity; a rear panel extending between a rear side of the first stud and a rear side of the second stud, the rear panel defining a rear side of the cavity; 2. The insulated building structure of embodiment 1, comprising a front panel extending between a front side of the first stud and a front side of the second stud, the front panel defining a front surface of the cavity.

[0086] Embodiment 3. An insulated building structure as described in embodiment 1 or embodiment 2, wherein each shelf has a first end adjacent to a first surface defining the cavity and a second end distal to the first surface and spaced apart from a second surface defining the cavity, the second surface being opposite the first surface.

[0087] Embodiment 4. An insulated building structure as described in any one of embodiments 1 to 3, wherein one or more of the shelves have a first end adjacent to a first side of the cavity and a second end distal to the first side of the cavity and spaced apart from a second side of the cavity.

[0088] Embodiment 5. An insulated building structure as described in any one of embodiments 1 to 4, wherein one or more of the shelves have a first end adjacent to the second side of the cavity and a second end distal to the second side of the cavity and spaced apart from the first side of the cavity.

[0089] Embodiment 6. An insulated building structure as described in any one of embodiments 1 to 5, wherein one or more of the shelves have a first end adjacent a front side of the cavity and a second end distal to the front side of the cavity and spaced apart from a rear side of the cavity.

[0090] Embodiment 7. An insulated building structure as described in any one of embodiments 1 to 6, wherein one or more of the shelves have a first end adjacent to the rear surface of the cavity and a second end distal to the rear surface of the cavity and spaced apart from the front surface of the cavity.

[0091] Embodiment 8. An insulated building structure according to any one of embodiments 3-7, wherein one or more of the shelves (e.g., each of the shelves) is angled relative to the plane, and the top major surface of the shelf is higher at its second end than at its first end.

[0092] Embodiment 9. The insulated building structure of embodiment 8, wherein the top major surface of each shelf forms an angle with respect to the plane of up to 45 degrees, such as up to 30 degrees, or in the range of 5 to 45 degrees, or 15 to 45 degrees, or 5 to 30 degrees.

[0093] Embodiment 10. The insulated building structure of any one of embodiments 1-9, comprising at least four shelves, such as at least six shelves or at least twelve shelves.

[0094] Embodiment 11. The insulated building structure of any one of embodiments 1-10, wherein the one or more shelves include a first shelf and a second shelf positioned directly below the first shelf.

[0095] Embodiment 12. The one or more shelves include a first shelf and a second shelf; a first shelf having a first end adjacent a first surface defining the cavity and a second end distal to the first surface and spaced apart from a second surface opposite the first surface; An insulated building structure as described in any one of embodiments 1 to 11, wherein the second shelf has a first end adjacent to the second surface and a second end distal to the second surface and spaced apart from the first surface.

[0096] Embodiment 13. The insulated building structure of embodiment 12, wherein the first surface is the first side surface.

[0097] Embodiment 14. The insulated building structure of embodiment 12, wherein the first surface is a front panel or a rear panel.

[0098] Embodiment 15. An insulated building structure according to any one of embodiments 1 to 14, wherein the rear surface defining the cavity is provided by wallboard, lath and plaster, or cladding, and the front panel defining the cavity is provided by a sheet of flexible material, such as fabric, mesh, or plastic sheeting.

[0099] Embodiment 16. An insulated building structure according to any one of embodiments 1 to 15, wherein the cavity extends longitudinally (e.g., the studs are positioned) at an angle of 60 degrees or less from the vertical, e.g., 45 degrees or less from the vertical.

[0100] Embodiment 17. An insulated building structure according to any one of embodiments 1 to 16, wherein each shelf has an enclosed area of ​​90% or less (e.g., 80% or less, 70% or less, 60% or less, or 50% or less) of the cross-sectional area of ​​the cavity.

[0101] Embodiment 18. An insulated building structure according to any one of embodiments 1-17, wherein each of the shelves has an enclosed area of ​​at least 5% (e.g., at least 10%, at least 15%, or at least 20%) of the cross-sectional area of ​​the cavity.

[0102] Embodiment 19. An insulated building structure according to any one of embodiments 1 to 18, wherein each shelf has an obstruction area in the range of 5 to 90% of the cross-sectional area of ​​the cavity, for example, 5 to 80%, or 5 to 70%, or 5 to 60%, or 5 to 50%, or 10 to 90%, or 10 to 80%, or 10 to 70%, or 10 to 60%, or 10 to 50%, or 15 to 90%, or 15 to 80%, or 15 to 70%, or 15 to 60%, or 15 to 50%, or 15 to 90%, or 20 to 80%, or 20 to 70%, or 20 to 60%, or 20 to 50%.

[0103] Embodiment 20. The insulated building structure of any one of embodiments 1-19, wherein the average insulation height in the longitudinal direction is 4 feet or less, e.g., 3 feet or less, or 2 feet or less.

[0104] Embodiment 21. An insulated building structure according to any one of embodiments 1 to 20, wherein the maximum possible insulation height in the longitudinal direction is 4 feet or less, e.g., 3 feet or less, or 2 feet or less.

[0105] Embodiment 22. The insulated building structure of any one of embodiments 1-21, wherein the insulated building structure is prefabricated and not installed as part of a building.

[0106] Embodiment 23. An insulated building structure as described in any one of embodiments 1 to 22, wherein the insulation used to insulate the structure is an insulation that achieves a k value of 0.31 or less at densities of 0.37 lbs / cubic foot or greater, a k value of 0.29 or less at densities of 0.6 lbs / cubic foot or greater, a k value of 0.27 or less at densities of 0.7 lbs / cubic foot or greater, a k value of 0.26 or less at densities of 0.8 lbs / cubic foot or greater, a k value of 0.25 or less at densities of 1.0 lbs / cubic foot or greater, a k value of 0.24 or less at densities of 1.2 lbs / cubic foot or greater, or a k value of 0.23 or less at densities of 1.3 lbs / cubic foot or greater.

[0107] Embodiment 24. A method of insulating a building cavity (e.g., forming an insulated building cavity according to any of embodiments 1-23), comprising: To provide a building structure, the building structure comprising: a longitudinally extending cavity bounded by a first side, a second side, a rear surface, and a front surface, the cavity having a cross-sectional area in a plane perpendicular to a longitudinal axis of the cavity; one or more shelves extending into the cavity, each having an enclosed area in a plane that is less than a cross-sectional area of ​​the cavity; and placing loose-fill insulation within the cavity so as to be positioned above and below each of the shelves.

[0108] Embodiment 25. The method of embodiment 24, wherein the building structure is any one of embodiments 2 to 23.

[0109] Embodiment 26. The method of embodiment 24 or 25, wherein the loose-fill insulation is placed into the cavity by blowing it in.

[0110] Embodiment 27. The method of any one of embodiments 24-26, wherein the insulating material is introduced into the cavity in no more than three locations.

[0111] Embodiment 28. The method of any one of embodiments 24-27, wherein the building structure is not installed as part of the building when the loose-fill insulation is placed in the building.

[0112] Embodiment 29. The method of embodiment 28, wherein the building structure is positioned such that when the loose-fill insulation is placed therein, its longitudinal extension is within 15 degrees of horizontal, e.g., within 5 degrees of horizontal.

[0113] Embodiment 30. The method of embodiment 28 or 29, wherein after the loose-fill insulation is placed in the cavity, the building structure is moved to the construction site and installed as part of the building.

[0114] It will be apparent to those skilled in the art that various modifications and variations can be made to the processes and devices described herein without departing from the scope of the present disclosure. Thus, the present disclosure is intended to cover all such modifications and variations of the present invention provided they come within the scope of the appended claims and their equivalents.

Claims

1. An insulated building structure, comprising: a longitudinally extending cavity bounded by a first side, a second side, a rear surface, and a front surface, the cavity having a cross-sectional area in a plane perpendicular to a longitudinal axis of the cavity; one or more shelves extending into the cavity, each having an enclosed area in the plane that is less than the cross-sectional area of ​​the cavity; loose-fill insulation disposed within the cavity, the loose-fill insulation positioned above and below each of the shelves; Equipped with one or more of the shelves having a first end adjacent the second side of the cavity and a second end distal to the second side of the cavity and spaced apart from the first side of the cavity.

2. The building structure is a first stud defining the first side of the cavity; a second stud laterally spaced from the first stud, the second stud defining the second side of the cavity; a rear panel extending between a rear side of the first stud and a rear side of the second stud, the rear panel defining the rear side of the cavity; a front panel extending between a front side of the first stud and a front side of the second stud, the front panel defining the front of the cavity; 10. The insulated building structure of claim 1, comprising:

3. 2. The insulated building structure of claim 1, wherein each of the shelves has a first end adjacent a first surface defining the cavity and a second end distal to the first surface and spaced apart from a second surface defining the cavity, the second surface being opposite the first surface.

4. 4. The insulated building structure of claim 3, wherein one or more of the shelves are angled relative to the plane, a top major surface of the shelf being higher at the second end than at the first end, and the top major surface of each of the shelves forming an angle with respect to the plane in the range of 5 to 45 degrees.

5. 2. The insulated building structure of claim 1, wherein one or more of the shelves have a first end adjacent the first side of the cavity and a second end distal the first side of the cavity and spaced apart from the second side of the cavity.

6. 2. The insulated building structure of claim 1, wherein one or more of the shelves have a first end adjacent the front surface of the cavity and a second end distal from the front surface of the cavity and spaced apart from the rear surface of the cavity.

7. 2. The insulated building structure of claim 1, wherein one or more of the shelves have a first end adjacent the rear face of the cavity and a second end distal from the rear face of the cavity and spaced apart from the front face of the cavity.

8. 10. The insulated building structure of claim 1 comprising at least four shelves.

9. the one or more shelves include a first shelf and a second shelf; the first shelf has a first end adjacent a first surface defining the cavity and a second end distal to the first surface and spaced apart from a second surface opposite the first surface; 10. The insulated building structure of claim 1, wherein the second shelf has a first end adjacent the second surface and a second end distal the second surface and spaced apart from the first surface.

10. 10. The insulated building structure of claim 9, wherein the first surface is the first side surface.

11. An insulated building structure as described in claim 9, comprising a rear panel defining the rear surface of the cavity and a front panel defining the front surface of the cavity, wherein the first surface is the front panel or the rear panel.

12. 10. The insulated building structure of claim 1, wherein the rear surface defining the cavity is provided by wallboard, lath and plaster, or cladding, and the front panel defining the cavity is provided by a sheet of flexible material such as fabric, mesh, or plastic sheeting.

13. 10. The insulated building structure of claim 1, wherein the cavity extends longitudinally at an angle of 60 degrees or less from the vertical.

14. 10. The insulated building structure of claim 1, wherein each of said shelves has an enclosed area in the range of 5 to 90% of said cross-sectional area of ​​said cavity.

15. 10. The insulated building structure of claim 1, wherein the insulated building structure is prefabricated and not installed as part of a building.

16. A method for insulating a building cavity, comprising providing the building cavity according to any one of claims 1 to 15, A building structure is provided, the building structure comprising: a longitudinally extending cavity bounded by a first side, a second side, a rear surface, and a front surface, the cavity having a cross-sectional area in a plane perpendicular to a longitudinal axis of the cavity; one or more shelves extending into the cavity, each having an enclosed area in the plane that is less than the cross-sectional area of ​​the cavity; and placing loose-fill insulation within the cavity so as to be positioned above and below each of the shelves.

17. 17. The method of claim 16, wherein the loose-fill insulation is placed into the cavity by blowing it in.

18. The method of claim 16 , wherein the insulation is introduced into the cavity in no more than three locations.

19. 17. The method of claim 16, wherein the building structure is not installed as part of a building when the loose-fill insulation is placed therein, and the building structure is positioned such that the longitudinal extension of the loose-fill insulation when placed therein is within 15 degrees of horizontal.

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