Loose-fill insulated building structure and method of manufacturing the same

Abstract

The present disclosure relates to an insulated building structure. In one aspect of the present disclosure, the insulated building structure comprises: a longitudinally extending cavity bounded by a first lateral surface, a second lateral surface, a rear surface, and a front surface—the cavity having a cross-sectional area in a plane perpendicular to the longitudinal axis of the cavity—; one or more shelves extending into the cavity and each having a closed area in a plane smaller than the cross-sectional area of ​​the cavity; and loose-fill insulation disposed within the cavity and positioned above and below each of the shelves.

Description

Technology Field

[0001] Cross-reference regarding related applications

[0002] This application claims the benefit of priority of U.S. provisional patent application No. 63 / 064964 filed on August 13, 2020, the entire contents of which are incorporated herein by reference.

[0003] Technology field

[0004] The present disclosure generally relates to a system and method for supporting loose-fill insulation, such as blown-in insulation, to reduce its settling. Background Technology

[0005] Insulating materials, such as fiberglass batts, rolls, blankets, or blown 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 inner surface of the roof deck to slow down the transfer of heat through the roof deck—that is, from the outside of the house to the attic or vice versa. In other applications, insulating materials are applied to exterior walls (e.g., between timber studs) and covered with wall panels to slow down the rate of heat transfer through the exterior walls and wall panels. Insulating materials can also prevent undesirable air movement (e.g., convective drafts) and the resulting movement of moisture from one space to another.

[0006] Some of these types of insulators, such as blown-in insulators, use loose-fill materials to fill wall cavities. These loose-fill insulators can be installed quickly in walls and ceilings and can be installed within wall cavities through small holes in the walls. However, over time, the weight of the loose-fill insulator can compress and cause the insulator to settle. This settling can result in varying amounts of insulation in different parts of the wall. In some cases, the settling can be severe enough to cause a void or gap between the outer and inner surfaces of the cavity, where no insulation will be present at all. However, even where no actual void or gap exists, the reduced amount of insulation in certain parts of the wall can cause undesirable heat loss through the wall.

[0007] Therefore, an improved method and system for supporting loose-fill insulators is required.

[0008] One aspect of the present disclosure is an insulated building structure, wherein the insulated building structure is

[0009] A longitudinal-extended cavity bounded by a first lateral surface, a second lateral surface, a rear surface, and a front surface - the cavity has a cross-sectional area in a plane perpendicular to the longitudinal axis of the cavity -;

[0010] One or more shelves extending into the cavity and each having a closed area in the plane smaller than the cross-sectional area of ​​the cavity; and

[0011] It includes loose-fill insulators placed within the cavity and positioned above and below each of the shelves.

[0012] In a given embodiment, the building structure

[0013] A first stud defining a common first lateral surface;

[0014] A second stud spaced laterally from the first stud and defining a second lateral surface of the cavity;

[0015] A rear panel extending between the rear surface of the first stud and the rear surface of the second stud and defining the joint rear surface;

[0016] It includes a front panel that extends between the front surface of the first stud and the front surface of the second stud and defines the front surface of the cavity.

[0017] Another aspect of the present disclosure is a method for insulating a building structure, wherein the method

[0018] Step of providing building structures - building structures

[0019] A longitudinal-extended cavity bounded by a first lateral surface, a second lateral surface, a rear surface, and a front surface - the cavity has a cross-sectional area in a plane perpendicular to the longitudinal axis of the cavity -; and

[0020] Includes one or more shelves extending into the cavity and each having a closed area smaller than the cross-sectional area of ​​the cavity in the plane -; and

[0021] The step includes placing loose-fill insulators within the cavity so that the loose-fill insulators are positioned above and below each of the shelves.

[0022] Further aspects of the present disclosure will be apparent from the disclosure of this specification. Brief explanation of the drawing

[0023] The attached drawings are incorporated into this specification to provide further understanding of the methods and apparatus of the present disclosure and constitute part of this specification. The drawings are not necessarily drawn to scale, and the sizes of various elements may be distorted for clarity. The drawings illustrate one or more embodiment(s) of the present disclosure and serve to explain the principles and operations of the present disclosure together with the description. FIG. 1 is a schematic front view of an insulated wall of the prior art. FIG. 2 is a schematic cross-sectional view of an insulated wall according to one embodiment of the present disclosure. FIG. 3 is a schematic cross-sectional view of an insulated wall according to an alternative embodiment of the present disclosure. FIG. 4 is a schematic cross-sectional view of an insulated wall according to another alternative embodiment of the present disclosure. FIG. 5 is a schematic cross-sectional view of a method for insulating a wall according to one embodiment of the present disclosure. FIG. 6 is a schematic cross-sectional view of a wall having a shelf for supporting an insulator according to an alternative embodiment of the present disclosure. FIG. 7 is a schematic cross-sectional view of a wall having a shelf for supporting an insulator according to another alternative embodiment of the present disclosure. FIG. 8 is a schematic cross-sectional view of a wall having a shelf for supporting an insulator according to another alternative embodiment of the present disclosure. Figure 9 is a graph of apparent thermal conductivity versus density of some insulating materials used as building insulators. Specific details for implementing the invention

[0024] As mentioned above, the inventors noted certain disadvantages of existing processes for insulating building structures such as walls, sloped ceilings, and roofs.

[0025] Accordingly, one aspect of the present disclosure is an insulated building structure. Such a structure will often take the form of a wall, as described in connection with the drawings below, but those skilled in the art will understand that other uses are possible, such as in a sloping ceiling or roof. In practice, the method and structure described herein may be used for any desired plane, e.g., a vertical plane, a horizontal plane, or a cavity structure having a portion extending in an inclined direction. The insulated building structure comprises a longitudinally extending cavity bounded by a first lateral surface, a second lateral surface, a rear surface, and a front surface—the cavity having a cross-sectional area in a plane perpendicular to the longitudinal axis of the cavity—and one or more shelves extending into the cavity and each having a closed area in a plane smaller than the cross-sectional area of ​​the cavity. Loose-fill insulation is disposed within the cavity, located both above and below each of the shelves.

[0026] In one typical configuration, an insulated building structure comprises: a first stud defining a first lateral surface of the cavity; a second stud laterally spaced from the first stud and defining a second lateral surface of the cavity; a rear panel extending between the rear faces of the first and second studs and defining a rear surface of the cavity; and a front panel extending between the front faces of the first and second studs, wherein the front panel defines a front surface of the cavity, so that the two studs and the two panels define the cavity between them. The longitudinal axis of the first stud defines the longitudinal axis of the cavity. One or more shelves disposed within the cavity are located between the first stud and the second stud. As used herein, the term “stud” includes other substantially linear framing members, including joists.

[0027] Another aspect of the present disclosure is a method for insulating a building cavity, e.g., a wall cavity. The method comprises the steps of providing a structure as described herein (i.e., a cavity in which one or more shelves extend internally), and applying a loose-fill insulation within the cavity such that each of the one or more shelves has an insulator disposed above and below it.

[0028] Compared to other systems for insulating building cavities with loose-fill insulation, the disclosed system and method may be advantageous in that, in certain embodiments, the shelves or shelves support at least a portion of the weight of the insulation. As such, the weight supported by the shelves does not act on the insulation located beneath the shelves, thereby reducing compression and subsidence of the insulation over time.

[0029] Compared to other systems for insulating building cavities with loose-fill insulation, the disclosed system and method, in certain embodiments, may provide the advantage of providing additional surface area for the shelves or shelves to support the weight of the loose-fill insulation, thereby allowing for a more uniform insulation distribution throughout the structure. The additional surface area provides a greater opportunity for friction between the fibers of the insulation and the shelves and other cavity surfaces, and this friction will reduce the compression or settling of the insulating material over time.

[0030] The subsidence of the insulator can result from vibrations that the cavity may experience at any point in its service life. This can occur during the installation process of the insulator into the cavity, after the cavity has experienced shock (due to an earthquake or other seismic event), or when a pre-filled cavity is transported from the manufacturing site to the final use site. Even changes in orientation to a vertical position for assembly into a larger structure or for filling a cavity that may be assembled at an angle in the manufacturing environment can cause subsidence.

[0031] In particular, the size and arrangement of one or more shelves may be selected by a person skilled in the art so that an insulator can be blown through them during installation. In a given embodiment, each of the shelves has a first end adjacent to a first surface defining the cavity and a second end located distal to the first surface and spaced apart from a second surface defining the cavity, the second surface being opposite to the first surface. For example, in a given embodiment as otherwise described herein, one or more of the shelves have a first end adjacent to a first lateral surface of the cavity and a second end located distal to the first lateral surface of the cavity and spaced apart from a second lateral surface of the cavity. In a given embodiment as otherwise described herein, one or more of the shelves have a first end adjacent to a second lateral surface of the cavity and a second end located distal to the second lateral surface of the cavity and spaced apart from a first lateral surface of the cavity. In a predetermined embodiment as otherwise described herein, one or more of the shelves have a first end adjacent to the front surface of the cavity and a second end distal to the front surface of the cavity and spaced apart from the rear lateral surface of the cavity. In a predetermined embodiment as otherwise described herein, 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.

[0032] In a given embodiment as otherwise described in this specification, one or more of the shelves (e.g., each of the shelves) are inclined with respect to a plane such that their main upper surface is higher at their second end than at their first end. The angle of the main upper surface of the shelf with respect to the plane may be, for example, up to 45 degrees, e.g. up to 30 degrees, or in the range of 5 to 45 degrees, or 15 to 45 degrees, or 5 to 30 degrees.

[0033] In many cases, there will be multiple shelves within the cavity, for example, at least 4 shelves, at least 6 shelves, or even at least 12 shelves.

[0034] Now, referring to the drawings, FIG. 1 is a front view of a portion of an embodiment of a conventional wall (10) in which a loose-fill insulator (20) is disposed within its cavity. The wall (10) comprises studs (12A, 12B, 12C) each having a height of H. In the embodiment of FIG. 1, an upper plate (11) extends along the upper end of the studs (12A, 12B, 12C). A sill plate or lower plate (13) extends along the lower end of the studs (12A, 12B, 12C). The wall (10) further comprises a rear panel (17) extending between the rear faces of the studs (12A, 12B, 12C). The wall (10) further comprises a front panel (not shown) extending along the front faces of the studs (12A, 12B, 12C). The studs and panels define a cavity (14A) (between stud (12A) and stud (12B)) and a cavity (14B) (between stud (12B) and stud (12C)), wherein the cavity (14A) and the cavity (14B) are also vertically defined by plates.

[0035] Those skilled in the art will understand that the materials of the structures described herein may vary. Studs may be formed of, for example, wood or metal. The front and rear panels may be formed of the same material or different materials. Each may be formed of a material that serves as the external surface of the structure, such as wall board, lath and plaster, or sheathing (e.g., gypsum board, oriented strand board (OSB), fiberboard, plywood, foam board, brick, masonry, monolithic block, stone, or other common construction materials). However, those skilled in the art will understand that insulation is often blown into the building cavity before the cavity is closed with its final surface material. In such cases, a sheet of flexible material, such as fabric, mesh, or plastic sheet, serves as a front panel that closes the cavity for the purpose of blowing in loose-fill insulation. An opening may be provided in this sheet to allow access of a tube to the cavity for blowing in the insulation. These sheets may later be covered with surface materials such as wallboards, lath and plaster, or seeding. In a given embodiment as otherwise described herein, the rear surface defining the cavity is provided by wallboards, lath and plaster, or seeding, and the front panel defining the cavity is provided by a sheet of flexible material such as fabric, mesh, or plastic sheet.

[0036] In the embodiment of FIG. 1, the cavities (14A, 14B) have the same height (H) as the studs (12A, 12B, 12C). Each of the cavities (14A, 14B) has a width (W) equal to the distance between two studs. For example, if the studs (12A, 12B, 12C) are standard two-by studs spaced according to a sixteen inch on center pattern, the width (W) is approximately 14.5 inches. Similarly, if the studs (12A, 12B, 12C) are standard two-by studs spaced according to a 24 inch on center pattern, the width (W) is approximately 22.5 inches. However, these are merely examples, and those skilled in the art will understand that other widths (W) are considered herein. The cavities (14A, 14B) have a depth (D) approximately equal to the depth of the studs (12A, 12B, 12C). For example, the depth (D) is approximately 3.5 inches for 2 x 4 studs, approximately 5.5 inches for 2 x 6 studs, and approximately 7.25 inches for 2 x 8 studs. As described above, other depths are considered herein.

[0037] Accordingly, each of the cavities (14A, 14B) has a cross-sectional area of ​​W x D in a plane perpendicular to the longitudinal axis (L) of the first stud (12A), for example, a horizontal plane relative to the vertical wall.

[0038] As described, each of the cavities (14A, 14B) contains a loose-fill insulator (20). However, the loose-fill insulator (20) is compressed and settled, leaving a void (21) near the top of the cavities (14A, 14B).

[0039] Referring to FIG. 2, a system (100) for insulating building cavities is illustrated. The system (100) includes studs (112A, 112B, 112C), an upper plate (111), and a lower plate (113) substantially similar to those illustrated in FIG. 1 and described above. The system (100) further includes a rear panel (117) and a front panel (116) (see FIG. 5) substantially similar to those described above. The studs (112A, 112B, 112C), panels, and plates (111, 113) define cavities (114A, 114B). Each of the cavities (114A, 114B) has a height of H, a width of W, and a depth of D (see FIG. 1). Accordingly, each of the cavities has a cross-sectional area equal to W x D in a plane perpendicular to the longitudinal axis (L) of the first stud (112A).

[0040] In the embodiments described herein, the system (100) forms a vertical wall (101), and thus 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, 112C) are ceiling joists. In a certain embodiment as otherwise described herein, the cavity extends longitudinally at an angle of 60 degrees or less from the vertical, for example, 45 degrees or less from the vertical (for example, the studs are positioned at said angle). In a certain embodiment as otherwise described herein, the cavity extends longitudinally at an angle of 30 degrees or less from the vertical, for example, 15 degrees or less from the vertical (for example, the studs are positioned at said angle). In a certain embodiment, the cavity extends longitudinally at an angle of 5 degrees or less from the vertical (for example, the studs are positioned at said angle). The system described in this specification is particularly advantageous in cavities that extend substantially vertically, because in such cavities, the settling of loose-fill insulators is a more significant problem.

[0041] The system (100) of FIG. 2 further comprises a plurality of shelves (130A to 130C) located within each cavity (114A, 114B). In this embodiment, each of the shelves (130A to 130C) is substantially similar. The shelf (130A) is described in more detail below as an exemplary embodiment.

[0042] The shelf (130A) of the embodiment of FIG. 2 includes a first end (131) and a second end (132). The first end is adjacent to a surface (118) defining one edge of the cavity (114A). In the illustrated embodiment, the surface (118) adjacent to the first end (131) of the shelf (130A) is a first stud (112A). In some embodiments, the first end (131) is joined to the stud (112A). The second end (132) is opposite the first end (131) and is distal from the adjacent surface (e.g., the first stud (112A)). In a preferred embodiment, the shelf is inclined with respect 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). Accordingly, the weight of the first part (120A) of the insulator located above the first shelf (130A) partially acts to hold the said part (120A) of the insulator toward the first stud (112A).

[0043] The shelf (130A) has a depth of less than D. As illustrated, the shelf has a width (W2) smaller than the width (W) of the cavity (114A). Thus, the shelf (130A) has a closed area smaller than W x D in a plane perpendicular to L.

[0044] The second end (132) of the shelf (130A) is spaced apart from the opposite surface (119) on the surface (118). There is an opening (133A) adjacent to the second end (132) of the shelf (130A), through which the insulator can flow from above the shelf (130A) to below the shelf (130A). During operation, the insulator is blown into the cavity (120A) from a single point. The installation point may be a hole in a wall or in a film or blanket defining the front surface of the cavity. Alternatively, the installation point may be the top of the wall penetrating the upper plate (111). During installation, the insulator passes through the openings (133A, 133B, 133C) to fill each section (115A, 115B, 115C) of the cavity (114A). After installation, the insulator is partially divided into sections (120A, 120B, 120C, 120D) by shelves (130A, 130B, 130C). The shelves (130A, 130B, 130C) partially support the weight of the sections (120A, 120B, 120C) of the insulator located on the shelves. This reduces the amount of pressure acting to compress the insulator located below each shelf.

[0045] FIG. 3 illustrates a system (200) having an alternative arrangement of shelves (230A, 230B, 230C). The odd shelves (230A, 230C) are substantially similar to the corresponding shelves (130A, 13C) illustrated in FIG. 2 and discussed above. The even shelves (230B) are mirrored with respect to the corresponding shelves (130A) illustrated above.

[0046] The system (200) includes a first shelf (230A) having a first end (231) coupled to a first stud (112A). The first shelf (230A) extends into a cavity (114A) toward a second stud (112B). There is an opening (233A) between the second end (232) of the first shelf (230A) and the second stud (112B).

[0047] The system further includes a second shelf (230B) having a first end (231) coupled to a second stud (112B). The second shelf (230B) extends into a cavity (114A) toward the first stud (112A). There is an opening (233B) between the second end (232) of the second shelf (230B) and the first stud (112A).

[0048] As illustrated, the first opening (233A) and the second opening (233B) are laterally offset from each other. Thus, the insulator immediately above the first opening (233A) is at least partially supported by the second shelf (230B). Similarly, the insulator immediately above the second opening (233B) is at least partially supported by the third shelf. Offsetting the openings (233A to 233C) in this way reduces the amount of force acting to compress the insulator in alignment with the openings (233A to 233C).

[0049] The illustrated embodiment shows three shelves (230A to 230C) within each cavity (114A, 114B), but it is understood that the embodiment is not limited to three shelves. The system (200) includes two or more shelves in an alternating arrangement spaced apart along the height (H) of the cavity (114A).

[0050] FIG. 4 illustrates a system (300) having a different arrangement of shelves (330A to 330F). As illustrated, the shelves are arranged in pairs (330A and 330B, 330C and 330D, 330E and 330F). Each pair of shelves is substantially the same height from one another and is installed at common locations along the height (H) of the cavity (114A). In this embodiment, the pairs of shelves are installed so that their angles are mirrored to one another; however, those skilled in the art will understand that other arrangements are possible. The shelves (330A to 330F) divide the insulator into sections (320A to 320D).

[0051] A shelf (330A) has a first end (331) adjacent to a first surface (118). In the illustrated embodiment, the first surface (118) is a first stud (112A). The shelf (330A) has a second end (332) distal from the first surface (118). A second shelf (330B) has a first end (331) adjacent to a second surface (119) opposite the first surface (118). In the illustrated embodiment, the second surface (119) is a second stud (112B). The second shelf (330B) has a second end (332) distal from the second surface (119). The second ends (332) of the two shelves (330A and 330B) are spaced apart from each other, defining an opening (333A) between them. As previously mentioned, the opening (333A) allows insulation to flow between the sections (115A, 115B) of the cavity (114A) during installation.

[0052] The remaining pairs (330C and 330D, 330E and 330F) are substantially similar to the aforementioned pairs (330A and 330B). In the illustrated form, the openings (333A to 333C) are aligned. However, it is understood that the lengths of the shelves (330A to 330F) can be adjusted to offset the openings for the reasons discussed above.

[0053] As illustrated, the shelf (330A) has a shorter width (W3) than the shelf (130A) of the embodiment of FIG. 2. Shortening the shelf (330A) in this way reduces the amount of torque on the joint between the first end (331) of the shelf (330A) and the first surface (118). The torque can be further reduced by attaching the second ends (332) of a pair of shelves (330A and 330B) by a plate located at the front and / or rear thereof.

[0054] Each of the above embodiments illustrates a system in which shelves are adjacent to the first stud (112A) and spaced apart from the second stud (112B), thus leaving an opening between the shelf and the second stud (112B) so that an insulator can flow through it. However, a similar effect can be achieved by having a shelf that extends the full width of a cavity (114A) adjacent to one of the rear panel and the front panel and spaced apart from the other of the rear panel and the front panel. Such an arrangement is illustrated in FIG. 5 and is discussed below.

[0055] FIG. 5 illustrates a system (400). FIG. 5 is a cross-sectional view of a cavity (114A) illustrating an upper plate (111), a lower plate (113), a front panel (116), and a rear panel (117). It is understood that the cavity (114A) is further defined by a first stud (112A) and a second stud (112B) as illustrated in a previous embodiment. The front panel (116) is formed from a flexible sheet, such as a blanket, to hold the insulator (420) in place during installation. When the wall is completed, the front panel (116) will be replaced or covered by a solid wall material such as shedding, wall board, or lath and plaster. Alternatively, the front panel (116) may be held in place and permanently covered by an additional layer of solid wall material such as shedding, wall board, or lath and plaster.

[0056] The system (400) includes a plurality of shelves (430A to 430C) arranged within the cavity (114A). The shelves (430A to 430C) are substantially similar. The first shelf (430A) is described below as an exemplary embodiment.

[0057] The shelf (430A) has a first end (431) adjacent to a first surface (418) that defines the cavity (114A). In the illustrated form, the first surface (418) is a rear panel (117). The shelf (430A) has a second end (432) distal from the first surface (418). The shelf (430A) is inclined with respect to a plane perpendicular to the axis (L) such that the second end (432) is higher than the first end (431).

[0058] The shelf (430A) extends across the entire width (W) of the cavity (114A). The shelf (430A) is joined to the first stud (112A) and the second stud (112B). However, the shelf (430A) has a depth (D2) lower than the depth (D) of the cavity (114A). Thus, the shelf (430A) has a closed area of ​​less than W x D in a plane perpendicular to the axis (L).

[0059] The second end (432) of the shelf (430A) is spaced apart from the front panel (116) to define an opening between them. FIG. 5 illustrates the installation process of the insulator (420). As illustrated, the hose (401) is positioned within the opening (402) of 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 insulator (420) is blown from the hose (401) into the cavity (114A). The insulator (420) flows through the opening (433A-C) between the shelf (430A-C) and the front panel (116) to fill each section (115A to 115D) of the cavity (114A). As in the previous embodiment, each shelf (430A to 430C) supports at least partially the weight of the section of insulator (420A to 420C) placed thereon.

[0060] The shelves (430A to 430C) are each adjacent to the same surface (418), but it is understood that other embodiments similar to those discussed above are considered herein. For example, an even shelf (430B) may be mirrored to be adjacent to the opposite surface (419) to offset the openings (433A to 433C) as in FIG. 3. Alternatively, the shelves (430A to 430C) may be arranged in pairs as shown in FIG. 4.

[0061] In another embodiment, the shelf may protrude from the rear panel without contacting the stud. In this case, the shelf may be attached to the rear panel and extend forward toward the front panel. In this given embodiment, the shelves extend by a distance less than W to serve to segment the cavity into zones where insulation can be constructed, but still have zones that allow insulation to be distributed to other zones within the cavity.

[0062] For example, in the various embodiments illustrated in FIGS. 6 through 8, the shelves are not connected to any of the studs (112A through 112C). Referring first to FIG. 6, the system (500) has a plurality of shelves (530A through 530D). The shelves (530A through 530D) are connected to the rear panel (117).

[0063] A shelf (530A) is positioned between the studs (112A, 112B). The shelf (530A) is spaced apart from both of the studs (112A, 112B). The shelf (530B) is spaced horizontally from the shelf (530A) and is also positioned between the studs (112A, 112B). The shelf (530B) is spaced apart from both of the studs (112A, 112B). Accordingly, the joint sections (115B, 115C) are connected by three channels (533A to 533C) to assist in the installation of a loose-fill insulator (not shown) as described above. As illustrated, the shelves (530A, 530B) are horizontal. However, the shelves can also be inclined, as in shelves (530C, 530D).

[0064] The shelves (530C and 530D) are located between the studs (112B, 112C). The shelves (530C and 530D) are spaced horizontally apart from each other and are each spaced horizontally apart from both studs (112B, 112C). Thus, the shelves (530C and 530D) similarly define three channels through which an insulator can flow.

[0065] Referring to FIG. 7, the system (600) includes a plurality of shelves (630A to 630C) having an arc shape. Each of the shelves (630A to 630C) is spaced apart from all the studs (112A-C) and is instead connected to the rear panel (117).

[0066] In some forms, the shelf (630A) has an upward arc shape. The upward arc shape is configured to support the insulator when the system (600) is in a vertical orientation. In alternative forms, the shelves (630B to 630C) have different orientations, such as one upward and one downward. The different orientations of the shelves provide support for the insulator when the system (600) is rotated or flipped, as in applications within a prefabricated structure as described below.

[0067] In some forms, the shelves (630B to 630C) are arranged in interlocking pairs. The first end of shelf (630B) interlocks with the second end of shelf (630C) to form a single continuous shelf. In an alternative form, additional interlocking shelves may be connected in turn to opposite ends of shelf (630B or 630C) to form a longer continuous shelf.

[0068] FIG. 8 illustrates a system (700) having additional alternative shelf shapes. The system (700) includes a stepped shelf (730A) and a V-shaped shelf (730B). The shelves (730A, 730B) are spaced apart from the studs (112A to 112C). The shelves (730A, 730B) are attached to the rear panel (117).

[0069] The stepped shelf (730A) has a first horizontal section (771) and a second horizontal section (772) connected by a vertical section (773). However, it is understood that the stepped shelf (730A) can be installed in an alternative orientation such that the parallel sections (771, 772) are vertical or inclined with respect to a vertical axis.

[0070] The V-shaped shelf (730B) is formed by two sections (775, 776) inclined relative to each other. 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 a support for the insulator in a different direction.

[0071] In each of the above embodiments, the shelf is indicated by a solid line. However, shelves formed of non-solid materials are considered herein. For example, any of the shelves discussed above may be formed of mesh, slats, rods, pins, or other materials. In some forms, the shelf is formed of wood, metal, or plastic having one or more openings penetrating it. The openings or openings of the non-solid shelf enable air flow through the shelf during pneumatic filling operations. This additional air flow helps to ensure a uniform distribution of insulation throughout the cavity.

[0072] Based on the disclosure of this specification, a person skilled in the art can select the size and pattern of the shelf that allows the loose-fill insulation to substantially fill the cavity while providing a reduced degree of insulation sedimentation in the blowing installation process.

[0073] Each shelf has an occluded area in a plane perpendicular to the longitudinal direction of the cavity. The occluded area is the cross-sectional area of ​​the cavity blocked by the shelf. As previously stated, the occluded area is smaller than the cross-sectional area of ​​the cavity (i.e., in a plane perpendicular to its longitudinal direction). In a certain embodiment as otherwise described herein, each shelf has an occluded area of ​​90% or less of the cross-sectional area of ​​the cavity. In a certain preferred embodiment, each shelf has an occluded area of ​​80% or less, 70% or less, 60% or less, or even 50% or less of the cross-sectional area of ​​the cavity. In a certain embodiment as otherwise described herein, each shelf has an occluded area of ​​at least 5% of the cross-sectional area of ​​the cavity. In a certain preferred embodiment, each shelf has an occluded area of ​​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 occluded area in the range of 5 to 90%, 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%. A person skilled in the art will select the shelf size along with the number of shelves to provide a configuration that allows the insulator to be blown through the shelves during insulation while also providing sufficient support for the insulator after installation.

[0074] In a given embodiment, each shelf has a depth of at least 25% of the depth of the cavity (i.e., at the location where it is placed). For example, in a given embodiment, each shelf has a depth of at least 40%, for example, at least 50%, or at least 60% of the depth of the cavity. Where the shelf does not extend to the full width of the cavity (for example, to 70% or less, 60% or less, or 50% or less of the width of the cavity), it may, in some embodiments, extend to the full depth of the cavity. In a given embodiment where the shelf extends to a significant fraction of the full width of the cavity (for example, at least 50%, at least 60%, or at least 70%), the shelf extends to 70% or less of the depth of the cavity, for example, 60% or less, or 50% or less, or 40% or less of the depth of the cavity. In a given embodiment as otherwise described in this specification, each shelf has a depth in the range of 25 to 100% of the depth of the cavity, for example, 25 to 70%, or 25 to 60%, or 25 to 50%, or 40 to 100%, or 40 to 70%, or 40 to 60%, or 50 to 100%, or 50 to 70%, or 60 to 100%.

[0075] In a given embodiment, each shelf has a width of at least 20% of the width of the cavity (i.e., at the location where it is placed). For example, in a given embodiment, each shelf has a width of at least 30%, for example, at least 40%, or at least 50% of the width of the cavity. Where the shelf does not extend to the full depth of the cavity (for example, to 70% or less, 60% or less, or 50% or less of the depth of the cavity), it may, in some embodiments, extend to the full width of the cavity. In a given embodiment where the shelf extends to a significant fraction of the full depth of the cavity (for example, at least 50%, at least 60%, or at least 70%), the shelf extends to 70% or less of the width of the cavity, for example, 60% or less, or 50% or less, or 40% or less of the width of the cavity. In a given embodiment as otherwise described in this specification, each shelf has a width in the range of 25 to 100% of the depth of the cavity, for example, 25 to 70%, or 25 to 60%, or 25 to 50%, or 40 to 100%, or 40 to 70%, or 40 to 60%, or 50 to 100%, or 50 to 70%, or 60 to 100%.

[0076] In a given embodiment, shelves are provided within the cavity such that the average insulator height, i.e., the average height of the insulator taken as the average height of the insulator in the longitudinal direction (e.g., parallel to the first stud) (between shelves, or between a shelf and the upper part of the body of the insulator, or between the lower part of the cavity and a shelf), is 4 feet or less. That is, the height of the body of the insulator between the support surfaces, averaged across the cavity, is 4 feet or less. For example, in a given embodiment as otherwise described herein, the average height of the insulator is 3 feet or less, e.g., 2 feet or less.

[0077] In a given embodiment, the shelf is positioned within the cavity such that the maximum possible longitudinal insulator height within the fully filled cavity is 4 feet or less. For example, in a given embodiment as otherwise described herein, the maximum possible longitudinal insulator height is 3 feet or less, for example, 2 feet or less.

[0078] The shelves may be arranged in various ways by those skilled in the art based on the disclosure of this specification. For example, in a given embodiment, the shelves are extended alternately, for example, between an extension from a first stud and an extension from a second stud, or alternately between an extension from a front panel and an extension from a rear panel. However, in another embodiment, the shelves extend across the entire cavity, for example, in the same direction from the rear panel.

[0079] Shelves can be formed from various materials, e.g., plastic, wood, fabric (e.g., supported or manufactured as rigid), cardboard, plaster, or metal. They can be attached to studs and / or panels in various ways, such as by nails, staples, screws, brackets, pressure-sensitive adhesive, or glue.

[0080] The present disclosure also provides a method for insulating a building structure, such as a wall, ceiling, or roof, as described above. The method comprises the step of providing a building structure in any configuration as described above, for example, the building structure comprises: a first stud; a second stud laterally spaced from the first stud; a rear panel extending between the rear face of the first stud and the rear face of the second stud; a front panel extending between the front face of the first stud and the front face of the second stud—the first stud, the second stud, the rear panel, and the front panel define a cavity between them having a first cross-sectional area in a plane perpendicular to the longitudinal axis of the first stud—; and a first shelf disposed within the cavity and having a closed area smaller than the first cross-sectional area in a plane. The method further comprises the step of placing a loose-fill insulator within the cavity such that the loose-fill insulator is positioned above and below each of the shelves. As described above, a plurality of shelves are disposed within the cavity to provide an improved support for the insulator during a blowing process, while still allowing the insulator to flow around the shelves; Loose-fill insulators will be placed above and below each of the shelves.

[0081] The building structure itself (i.e., not including an insulator) may be as described in any of the various embodiments above.

[0082] The methods and structures of the present disclosure may be useful in various construction situations. For example, a building structure including a shelf as described herein may be provided as part of a building and subsequently insulated by blowing in an insulator.

[0083] The inventors have also determined that the method and structure described herein may be particularly useful for the manufacture of prefabricated building structures. The prefabricated structure is formed from wall and / or ceiling sections manufactured off-site, such as in a factory, and subsequently installed on-site as part of a building. Accordingly, in certain embodiments as otherwise described herein, the insulated building structure is prefabricated and not installed as part of a building. Such an insulated building structure may be transported to a building site and subsequently installed as part of a building. In particular, during manufacturing, transport, and installation, the prefabricated wall may be flipped, shaken, or otherwise moved. Conveniently, the prefabricated building structure may be transported horizontally. In typical prefabricated wall or ceiling sections, this may cause the insulation to settle. A shelf reduces the amount of insulation settling as a result of such movement. In the method and structure described herein, a shelf may help prevent the insulation from settling during manufacturing, transport, and installation.

[0084] One method of manufacturing a structure comprises the step of assembling a wall with a plurality of studs, an upper plate, a base plate, and internal and external seedings, together with one or more shelves such as those shown in FIGS. 2 through 8, located within a cavity of the wall. The wall cavity is also filled with a loose-fill insulator.

[0085] In a method for manufacturing a prefabricated building structure, the insulator may be blown into a cavity already fabricated as described above, but in another embodiment, the insulator is distributed into the cavity before one of the rear surface and the front surface closes the cavity. This may allow the insulator to be deposited relatively uniformly over the entire cavity space more easily, and then the front or rear panel (e.g., a seeding) may be installed to close the cavity. One advantage of this installation is that there is no need to make holes in the fabric or seeding material. In a given embodiment, the building structure is positioned such that its longitudinal-extending direction is within 15 degrees of the horizontal, e.g., within 5 degrees of the horizontal, when the loose-fill insulator is placed inside it.

[0086] Various loose-fill insulating materials may be used in the practice of the methods and structures described herein. For example, known insulating materials include stonewool, rock wool, fiberglass, polyester, cellulose, polystyrene pellets, vermiculite, and cotton. These materials may be provided as binder-bonded materials or without binders, preferably without adhesives, liquids, and moisture that promote clumping and aggregation of fibers or nodules of the material. The loose-fill material may be a product specifically manufactured for installation in a cavity, such as Insulsafe® brand insulating (available from CertalTeed LLC), or may be an insulating material that was previously in the form of a bat or blanket and has been fragmented or cubicized to reduce particle size for transport into the cavity.

[0087] In a given embodiment as otherwise described herein, the insulator used to insulate the structure is 0.37 lbs / ft 3 At densities above this level, k-values ​​of 0.31 or less, 0.6 lbs / ft 3At densities above this level, k-values ​​of 0.29 or less, 0.7 lbs / ft 3 At densities above this level, k-values ​​of 0.27 or less, 0.8 lbs / ft 3 At densities above this level, k-values ​​of 0.26 or less, 1.0 lbs / ft 3 At densities above 0.25 k-value or less, 1.2 lbs / ft 3 At densities above this level, a k-value of 0.24 or less, and 1.3 lbs / ft² 3 It is an insulator that achieves a k-value of 0.23 or less at a density above.

[0088] A person skilled in the art may use any convenient technique to place loose-fill insulation. Such insulation is typically blown in through a tube, for example, through an opening in the front panel. In particular, since the loose-fill insulation can pass along the shelf during insulation, the insulation can be introduced into the cavity at a relatively small number of locations (for example, through a relatively small number of openings in the front panel). For example, in a given embodiment, the insulation is introduced into the cavity at three or fewer locations, for example, three locations, or two locations, or at only one location. In contrast, the insulation can be deposited manually or mechanically into a cavity positioned horizontally in the normal plane, as in a factory to create a prefabricated building structure, and thus attention can be paid to whether the insulation is installed at a specific density as well as a uniform density within the cavity space and along the surface of the shelf. The presence of the shelf can help prevent the settling of the insulation due to movement, transportation, and assembly into the building, as well as settling over time. Of course, those skilled in the art will understand that other techniques may be used to place insulators into the cavity as described in this specification.

[0089] The inventors noted that sedimentation of the insulator can significantly affect the overall insulation value of a building structure. In extreme cases, sedimentation can result in voids near the top of the wall; if the insulator is absent from part of the wall cavity, that part of the wall can allow heat to be efficiently transferred through it. However, even when no voids are formed, sedimentation can cause a change in the density of the insulator through the wall cavity. Figure 9 is a graph of apparent thermal conductivity versus density for several insulating materials used as building insulators. The graph demonstrates that differences in insulation density can dramatically affect the insulation quality of the insulator, particularly at lower insulation densities. For example, the density of rock wool or glass fiber / fiberglass insulation is 2 lbs / ft² 3 From 1 lbs / ft 3 Reducing it to this extent can increase apparent thermal conductivity by more than 20%. These regions of higher thermal conductivity form thermal channels that allow heat to pass through the walls more quickly, thereby lowering the overall U value of the structure. To protect against this, the insulation is conventionally installed at a density higher than nominally required for the desired insulation value, so that the insulation value can be maintained within the specification even after some settling. The use of shelves as described herein can help reduce the variability of insulation density and thus allow the use of relatively less insulating material to achieve the desired insulation value.

[0090] Referring to the graph in Fig. 9, the target insulation density is conventionally selected along the flat portion of the curve for a given material so that the decrease in density at a certain point due to sedimentation does not cause a significant increase in thermal conductivity (typically, 2.4 lbs / ft² for fiberglass insulation materials). 3 4 lbs / ft of excess and rock wool 3(Exceeding). Accordingly, to ensure that the desired level of insulation is maintained even if the density in a given area of ​​the structure is reduced due to sedimentation, conventional insulators are distributed at a density somewhat higher than strictly required. If shelves as described herein are used to support the insulators within the cavity, in a given embodiment, the need to be at an increased density may be reduced or eliminated. As such, in a given embodiment as otherwise described herein, 1.6 lbs / ft² for fiberglass insulators to provide an approximately equivalent thermal conductivity value or k value. 3 (30% reduction compared to conventional) or 3 lbs / ft² for rock wool insulation 3 An equivalent thermal performance density, such as the density of (a 25% reduction compared to conventional), can be selected. This density is closer to the edge of the dropoff of the insulation value in relation to the reduction in density, but the reduction in density as a result of the presence of the shelf is likely to be much smaller. Thus, as understood by those skilled in the art, at a similar k value (which is the inverse of the R-value), the wall section can meet the thermal R-value requirements with a significantly smaller mass of insulating material installed.

[0091] In a typical wall assembly, it is desirable to achieve R-11, R-13, R-14, or R-15 in a standard 2 x 4 wall stud cavity (actual depth (D) of 3.5 inches), or R-19, R-21, or R-24 in a standard 2 x 6 wall stud cavity (actual depth (D) of 5.5 inches), or R-29 or R-31 in a standard 2 x 8 wall stud cavity (actual depth (D) of 7.25 inches).

[0092] For a 2 x 4 wall stud cavity, an R-14 wall requires a k-value of 0.25, and an R-15 wall requires a k-value of 0.24. The more typical 1.6 to 2.4 lbs / ft required to ensure that sedimentation occurs without significantly affecting thermal conductivity. 3 1.0 lbs / ft² for fiberglass insulation relative to density 3 Achieving these k-values ​​closer to the target design density can reduce material usage by either 30% or 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 are 0.7 lbs / ft² for R-13. 3 Even for Low and R-11, 0.37 lbs / ft 3 It can be reduced to. These are the typical densities required in conventional cavity wall installations of loose-fill fiberglass materials—which is often a minimum of 1.2 lbs / ft² for a 2 x 4 configuration. 3 Citing the density of - is much lower than.

[0093] This effect can be much more pronounced for thicker wall sections. For an R-19 wall with a 2 x 6 stud cavity (5.5 inches deep (D)), a k-value of 0.29 is thermally required. However, to provide a certain degree of settling, 1.6 lbs / ft² 3 If a minimum density is required, the density needed to achieve a 0.29 k-value is only 0.6 lbs / ft 3 Therefore, these walls will be over-insulated. Achieving these thermal values ​​through the use of shelves as described herein can result in a 62% saving of the material used while still achieving the same overall R-value performance. Similarly, 0.8 lbs / ft 3The density can deliver the 0.26 k-value required for an R-21 wall in a 2 x 6 configuration (5.5 inches deep (D)). Finally, an R-24 wall in a 2 x 6 configuration (5.5 inches deep (D)) requires a k-value of 0.23 to achieve its thermal rating—which is now, typically specified as 1.6 lbs / ft². 3 Rather than above, 1.3 lbs / ft 3 This can be achieved (still saving over 18%).

[0094] For a 2 x 8 wall (7.25 inches deep (D)), a k-value of 0.25 is required to achieve R-29. This corresponds to 1.2 lbs / ft² as conventionally. 3 Although the recommended installation density is 1.0 lbs / ft², the desired k-value is 1.0 lbs / ft² instead of using a shelf to prevent sedimentation as described herein. 3 This can be achieved at a density 20% lower. As in the case of an R-31 wall (k-value of 0.24), 1.6 lbs / ft² 3 Compared to the conventional density of 1.2 lbs / ft when using a lathe as described herein 3 A density of can be provided (25% material reduction).

[0095] Since loose-fill insulation is typically sold in the form of bags or compressed bales of material, this reduction in density means that fewer bags of insulation material will be required to insulate the same space to the same R-value as required by appropriate local codes. This reduction implies more efficient use of natural resources, fewer bags of insulation that need to be lifted and handled by installers, and fewer bags of insulation that need to be delivered to the job site for installation—providing economic, environmental, and ergonomic improvements for all.

[0096] Additional aspects of the present disclosure are provided by the embodiments listed below, which may be combined in any number and in any way that is technically or logically consistent.

[0097] Embodiment 1. As an insulated building structure,

[0098] A longitudinal-extended cavity bounded by a first lateral surface, a second lateral surface, a rear surface, and a front surface - the cavity has a cross-sectional area in a plane perpendicular to the longitudinal axis of the cavity -;

[0099] One or more shelves extending into the cavity and each having a closed area in the plane smaller than the cross-sectional area of ​​the cavity; and

[0100] An insulated building structure comprising loose-fill insulators disposed within a cavity and located above and below each of the shelves.

[0101] Embodiment 2. In Embodiment 1, the building structure is

[0102] A first stud defining a common first lateral surface;

[0103] A second stud spaced laterally from the first stud and defining a second lateral surface of the cavity;

[0104] A rear panel extending between the rear surface of the first stud and the rear surface of the second stud and defining the rear surface of the cavity; and

[0105] An insulated building structure comprising a front panel extending between the front face of a first stud and the front face of a second stud and defining a common front surface.

[0106] Embodiment 3. An insulated building structure in Embodiment 1 or Embodiment 2, wherein each of the shelves has a first end adjacent to a first surface defining a cavity and a second end spaced apart from a second surface defining a cavity and distal to the first surface, and the second surface is on the opposite side of the first surface.

[0107] Embodiment 4. An insulated building structure in any one of embodiments 1 to 3, wherein one or more of the shelves have a first end adjacent to a first lateral surface of the cavity and a second end distal to the first lateral surface of the cavity and spaced apart from a second lateral surface of the cavity.

[0108] Embodiment 5. An insulated building structure in any one of embodiments 1 to 4, wherein one or more of the shelves have a first end adjacent to a second lateral surface of the cavity and a second end distal to the second lateral surface of the cavity and spaced apart from the first lateral surface of the cavity.

[0109] Embodiment 6. An insulated building structure in any one of embodiments 1 to 5, wherein one or more of the shelves have a first end adjacent to the front surface of the cavity and a second end distal to the front surface of the cavity and spaced apart from the rear lateral surface of the cavity.

[0110] Embodiment 7. An insulated building structure 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.

[0111] Embodiment 8. An insulated building structure in any one of embodiments 3 to 7, wherein one or more of the shelves (e.g., each of the shelves) are inclined with respect to a plane such that the main upper surface of the shelf is higher at its second end than at its first end.

[0112] Embodiment 9. An insulated building structure, wherein the main upper surface of each of the shelves in Embodiment 8 forms an angle with respect to a plane up to 45 degrees, e.g. up to 30 degrees, or in the range of 5 to 45 degrees, or 15 to 45 degrees, or 5 to 30 degrees.

[0113] Embodiment 10. An insulated building structure comprising at least four shelves, for example, at least six shelves or at least twelve shelves, in any one of embodiments 1 to 9.

[0114] Embodiment 11. An insulated building structure in any one of embodiments 1 to 10, wherein one or more shelves comprise a first shelf and a second shelf located immediately below the first shelf.

[0115] Embodiment 12. In any one of embodiments 1 to 11, one or more shelves include a first shelf and a second shelf, and

[0116] The first shelf has a first end adjacent to a first surface defining a cavity and a second end located at the distal end of the first surface and spaced apart from the second surface opposite the first surface, and

[0117] An insulated building structure having a second shelf having a first end adjacent to a second surface and a second end located at the distance of the second surface and spaced apart from the first surface.

[0118] Embodiment 13. An insulated building structure in Embodiment 12, wherein the first surface is a first lateral surface.

[0119] Embodiment 14. An insulated building structure in Embodiment 12, wherein the first surface is a front panel or a rear panel.

[0120] Embodiment 15. An insulated building structure in any one of embodiments 1 to 14, wherein the rear surface defining the cavity is provided by a wall plate, lath and plaster, or shedding, and the front panel defining the cavity is provided by a sheet of flexible material such as fabric, mesh, or plastic sheet.

[0121] Embodiment 16. An insulated building structure in any one of embodiments 1 to 15, wherein the cavity extends longitudinally at an angle of 60 degrees or less from the vertical, for example, 45 degrees or less from the vertical (for example, studs are arranged at said angle).

[0122] Embodiment 17. An insulated building structure in any one of embodiments 1 to 16, wherein each shelf has a closed area of ​​90% or less of the common cross-sectional area (e.g., 80% or less, 70% or less, 60% or less, or 50% or less).

[0123] Embodiment 18. An insulated building structure, wherein in any one of embodiments 1 to 17, each shelf has a closed area of ​​at least 5% (e.g., at least 10%, at least 15%, or at least 20%) of the common cross-sectional area.

[0124] Embodiment 19. An insulated building structure, wherein each of the shelves has a closed area in the range of 5 to 90%, 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%.

[0125] Embodiment 20. An insulated building structure in any one of embodiments 1 to 19, wherein the longitudinal average insulator height is 4 feet or less, e.g. 3 feet or less, or 2 feet or less.

[0126] Embodiment 21. An insulated building structure in any one of embodiments 1 to 20, wherein the maximum possible longitudinal insulator height is 4 feet or less, e.g. 3 feet or less, or 2 feet or less.

[0127] Embodiment 22. An insulated building structure in any one of embodiments 1 to 21, wherein the insulated building structure is prefabricated and is not installed as part of the building.

[0128] Embodiment 23. In any one of Embodiments 1 to 22, the insulator used to insulate the structure is 0.37 lbs / ft 3 At densities above this level, k-values ​​of 0.31 or less, 0.6 lbs / ft 3 At densities above this level, k-values ​​of 0.29 or less, 0.7 lbs / ft 3At densities above this level, k-values ​​of 0.27 or less, 0.8 lbs / ft 3 At densities above this level, k-values ​​of 0.26 or less, 1.0 lbs / ft 3 At densities above 0.25 k-value or less, 1.2 lbs / ft 3 At densities above this level, a k-value of 0.24 or less, and 1.3 lbs / ft² 3 Insulated building structure, which is an insulator achieving a k-value of 0.23 or less at a density above.

[0129] Embodiment 24. A method for insulating a building cavity (e.g., to form an insulated building cavity according to any one of Embodiments 1 to 23), wherein the present method

[0130] Step of providing building structures - building structures

[0131] A longitudinal-extended cavity bounded by a first lateral surface, a second lateral surface, a rear surface, and a front surface - the cavity has a cross-sectional area in a plane perpendicular to the longitudinal axis of the cavity -; and

[0132] Includes one or more shelves extending into the cavity and each having a closed area smaller than the cross-sectional area of ​​the cavity in the plane -; and

[0133] A method comprising the step of placing loose-fill insulators within a cavity such that the loose-fill insulators are positioned above and below each of the shelves.

[0134] Embodiment 25. Method in which, in Embodiment 24, the building structure is as described in any one of Embodiments 2 to 23.

[0135] Embodiment 26. A method in which, in Embodiment 24 or Embodiment 25, a loose-fill insulator is disposed within a cavity by being blown in.

[0136] Embodiment 27. A method in any one of embodiments 24 to 26, wherein the insulator is introduced into the cavity at three or fewer locations.

[0137] Embodiment 28. A method in any one of embodiments 24 to 27, wherein the building structure is not installed as part of the building when a loose-fill insulator is disposed therein.

[0138] Embodiment 29. The method of Embodiment 28, wherein the building structure is positioned such that when a loose-fill insulator is placed therein, its longitudinal-extending direction is within 15 degrees of the horizontal, for example, within 5 degrees of the horizontal.

[0139] Embodiment 30. A method in which, in Embodiment 28 or Embodiment 29, a loose-fill insulator is placed in a cavity, and then, a building structure is moved to a building site and installed as part of a building.

[0140] It will be apparent to those skilled in the art that various modifications and changes may be made to the processes and apparatus described herein without departing from the scope of this disclosure. Accordingly, this disclosure is intended to cover such modifications and changes to the invention if they fall within the scope of the appended claims and their equivalents.

Claims

Claim 1 An insulated building structure comprising: a longitudinally extending cavity bounded by a first lateral surface, a second lateral surface, a rear surface, and a front surface, said cavity having a cross-sectional area in a plane perpendicular to the longitudinal axis of said cavity; one or more shelves extending into said cavity and each having a closed area in said plane that is 20 to 80% of the cross-sectional area of ​​said cavity; and a loose-fill insulation disposed within said cavity and positioned above and below each of said shelves, said shelves each supporting at least a portion of the weight of the loose-fill insulation positioned immediately above the shelf, and one or more of said shelves having a first end adjacent to the second lateral surface of said cavity and spaced apart from the first lateral surface of said cavity. Claim 2 An insulated building structure according to claim 1, wherein the building structure comprises: a first stud defining the first lateral surface of the cavity; a second stud spaced laterally from the first stud and defining the second lateral surface of the cavity; a rear panel extending between the rear surface of the first stud and the rear surface of the second stud and defining the rear surface of the cavity; and a front panel extending between the front surface of the first stud and the front surface of the second stud and defining the front surface of the cavity. Claim 3 An insulated building structure according to claim 1 or 2, wherein one or more of the shelves are inclined with respect to the plane such that the main upper surface of the shelf is higher at its second end than at its first end, and the main upper surface of each of the shelves forms an angle ranging from 5 to 45 degrees with respect to the plane. Claim 4 An insulated building structure according to claim 1 or 2, wherein one or more of the shelves have a first end adjacent to the first lateral surface of the cavity and a second end located at the distance from the first lateral surface of the cavity and spaced apart from the second lateral surface of the cavity. Claim 5 An insulated building structure according to claim 1 or 2, wherein one or more of the shelves have a first end adjacent to the front surface of the cavity and a second end distal to the front surface of the cavity and spaced apart from the rear lateral surface of the cavity. Claim 6 An insulated building structure according to claim 1 or 2, 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. Claim 7 An insulated building structure according to claim 1 or 2, comprising at least 4 shelves, for example, at least 6 shelves or at least 12 shelves. Claim 8 An insulated building structure according to claim 1 or 2, wherein the one or more shelves comprise a plurality of first shelves and a plurality of second shelves, each first shelf having a first end adjacent to a first surface defining the cavity and a second end located at the distance of the first surface and spaced apart from a second surface opposite the first surface, and each second shelf having a first end adjacent to the second surface and a second end located at the distance of the second surface and spaced apart from the first surface. Claim 9 In paragraph 8, the above-mentioned first shelves alternate with the above-mentioned second shelves, an insulated building structure. Claim 10 An insulated building structure according to claim 1 or 2, wherein each shelf has a width of at least 40% and no more than 70% of the width of the common. Claim 11 In paragraph 2, the above cavity is an insulated building structure extending longitudinally at an angle of 60 degrees or less from the vertical, for example, 45 degrees or less from the vertical (for example, the studs are arranged at said angle). Claim 12 An insulated building structure according to claim 1 or 2, wherein each shelf has a closed area ranging from 20 to 70%, or from 20 to 60%, or from 20 to 50% of the cross-sectional area of ​​the common. Claim 13 A method for insulating a building cavity to provide a building cavity according to claim 1 or 2, comprising the steps of: providing a building structure comprising the longitudinal-extended cavity and one or more shelves; and placing a loose-fill insulator within the cavity such that the loose-fill insulator is positioned above and below each of the shelves. Claim 14 A method for insulating a building cavity according to claim 13, wherein the insulator is introduced into the cavity at three or fewer locations. Claim 15 A method of insulating a building cavity according to paragraph 13, wherein the building structure is not installed as part of the building when the loose-fill insulator is placed therein, and the building structure is positioned such that its longitudinal-extending direction is within 15 degrees of the horizontal when the loose-fill insulator is placed therein. Claim 16 delete Claim 17 delete Claim 18 delete Claim 19 delete Claim 20 delete

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