Method of Retrofitting Building Exteriors With Insulation And Cladding Construction

Abstract

A method of retrofitting a building exterior with an insulation and cladding construction has a multitude of steps. One step involves placing rigid panel insulation members to certain areas of the building exterior. A subsequent step involves spraying polyurethane insulation foam to certain areas of the building exterior. And yet another step involves spraying cladding over the rigid panel insulation members placed at the building exterior, and involves spraying the cladding over the previously-sprayed polyurethane insulation foam. The sprayed cladding cures in-place and, once cured, constitutes a continuous and monolithic cladding exterior construction over the placed rigid panel insulation members and over the sprayed polyurethane insulation foam.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 530,281, with a filing date of Aug. 2, 2023, the contents of which are hereby incorporated by reference in their entirety.TECHNICAL FIELD

[0002] The present disclosure relates generally to retrofitted building exteriors and, more particularly, to processes and procedures for retrofitting building exteriors with insulation and cladding constructions.BACKGROUND

[0003] Retrofitting existing homes for increased energy efficiency can involve augmenting insulation, installing high performance fenestrations, and sealing homes with air and vapor barriers. Exterior insulation, in particular, helps lower energy use in heating, ventilation, and air conditioning (HVAC) of homes, and helps with potential moisture issues encountered in walls. Previous exterior insulation approaches typically require the creation of an external installation for siding attachment that transmits loads exerted at the exterior back to a structure of the associated home. Common practices employ fastener part attachment of furring strips directly to each vertical stud of the home. In some cases, this is called-for in order to satisfy siding manufacturers' requirements and / or to comply with certain applicable international residential codes. But this approach and practice has proven costly and overly burdensome for installers due to—among other drawbacks—the time-consuming verification of fastener part attachment to ensure proper installation.SUMMARY

[0004] In an embodiment, a method of retrofitting a building exterior with an insulation and cladding construction may involve multiple steps. One step may involve the placement of rigid panel insulation members to first sections or more sections of the building exterior. Another step may involve the application of spray-on polyurethane insulation foam to second sections or more sections of the building exterior. Yet another step may involve the application of spray-on cladding over the already-placed rigid panel insulation members, and the application of spray-on cladding over the already-applied spray-on polyurethane insulation foam. The applied spray-on cladding resides at the first and second sections or at more sections of the building exterior. The applied spray-on cladding serves to join the already-placed rigid panel insulation members and the already-applied spray-on polyurethane insulation foam, and thereby establishes a continuous and monolithic cladding exterior construction.

[0005] In an embodiment, a method of retrofitting a building exterior with an insulation and cladding construction may involve multiple steps. One step may involve the attachment of rigid panel insulation members to generally flat areas of the building exterior. Another step may involve spraying-on polyurethane insulation foam to seam areas or more areas at the building exterior. The seam areas being established between adjacent and already-attached rigid panel insulation members. Yet another step may involve spraying-on cladding over the already-attached rigid panel insulation members, and spraying-on cladding over the already sprayed-on polyurethane insulation foam. The sprayed-on cladding constitutes a monolithic cladding exterior construction of the building.

[0006] In an embodiment, a method of retrofitting a building exterior with an insulation and cladding construction may involve multiple steps. One step may involve removing existing exterior structures at the building exterior. Another step may involve the placement of rigid panel insulation members to generally flat areas of the building exterior. Yet another step may involve spraying-on polyurethane insulation foam to some areas or more areas of the building exterior where the already-placed rigid panel insulation members are not present and are hence absent. And another step may involve spraying-on cladding over the already-placed rigid panel insulation members, and spraying-on cladding over the already sprayed-on polyurethane insulation foam. The sprayed-on cladding serves to join the already-placed rigid panel insulation members and the already sprayed-on polyurethane insulation foam together. Further, the sprayed-on cladding cures in-place over the already-placed rigid panel insulation members and over the already sprayed-on polyurethane insulation foam.

[0007] Further scope of applicability of the present disclosure will become apparent from the detailed description given hereinafter. But it should be understood that the detailed description and specific examples, while indicating exemplary embodiments of the disclosure, are given by way of illustration only, since various changes and modifications within the spirit and scope of the disclosure will become apparent to those skilled in the art from this detailed description.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The present disclosure will become more fully understood from the detailed description given below and the accompanying drawings, which are given by way of illustration only, and do not limit the present disclosure, and wherein:

[0009] FIG. 1 is a schematic depiction of a step involved in an embodiment of a method of retrofitting a building exterior with an insulation and cladding construction;

[0010] FIG. 2 is a schematic depiction of another step involved in the method of retrofitting a building exterior;

[0011] FIG. 3 is a schematic depiction of another step involved in the method of retrofitting a building exterior;

[0012] FIG. 4 is a schematic depiction of another step involved in the method of retrofitting a building exterior;

[0013] FIG. 5 presents images of certain industrial lignins (from upper left, clockwise): Kraft lignin (LignoBoost), Kraft lignin (Indulin AT), Organosolv lignin (Ethanol), and Lignosulfonate (Sulfite pulping);

[0014] FIG. 6 presents a tentative structural elucidation of pine lignin;

[0015] FIG. 7 depicts a lignin-isocyanate reaction;

[0016] FIG. 8 is a schematic depiction of lignin-based polyurethane (PU) foams obtained from different lignin sources and foam structure; and

[0017] FIG. 9 is a schematic depiction of a Mannich reaction highlighting amination of lignin subunits.DETAILED DESCRIPTION

[0018] Referring generally to the drawings, embodiments of a process and method of retrofitting building exteriors 10 with an insulation and cladding construction 12 are depicted in the figures and described herein. The method and construction furnishes a continuous and monolithic exterior insulation and cladding layer and envelop over buildings, and is a hybrid system in the sense that it combines insulative paneling and insulative foam spraying together via a cladding thereover, effectively leveraging the benefits of both insulation capabilities. Compared to past approaches, a simplified and faster installation procedure is provided with the process and method of retrofitting building exteriors 10 as set forth herein, as well as a minimization of labor and material costs. Moreover, the process and method herein can provide a reduction in disturbances to use and occupancy of the subject building. Furthermore, unlike the past approaches, fastener part attachment to exterior building structures-which often requires the transfer of loads to existing building structures (e.g., via furring strips to vertical studs) and is often overly burdensome in practice-is unneeded with the employment of the process and method of retrofitting building exteriors 10 set forth herein. And unlike adding insulation within wall cavities, another way to augment insulation and which usually requires drywall removal, the process and method herein does not cause drywall disruption.

[0019] Yet further, an overall more efficient and effective insulation and cladding exterior construction is depicted and described herein that can replace and improve obsolete building exteriors. The method and construction can provide enhanced structural integrity and durability at building exteriors, an increased insulative performance and R-value rating, an improved barrier to water and vapor intrusion, a more resilient weathering and longevity, and / or a greater ability to withstand weather hazards such as windstorms and tornadoes and hurricanes. Still, a particular embodiment of the process and method of retrofitting building exteriors 10 with the insulation and cladding construction 12 may exhibit only one, all, or a combination of, the advancements set forth herein, none of the advancements, or yet other advancements unmentioned.

[0020] Further, as used herein, the term “building” is intended to have an expansive meaning that encompasses commercial and non-commercial buildings, residential and non-residential buildings, single-and multi-family dwellings and housing, as well as other types of structures.

[0021] The method of retrofitting building exteriors 10 with the insulation and cladding construction 12 may have varied steps according to different embodiments, and may have more, less, and / or different steps than those presented herein. Indeed, the steps of the method may at least partly be dictated by the building subject to retrofitting and the desired and intended performance of the insulation and cladding exterior construction 12. The steps need not necessarily be performed in the particular order described and depicted. With general reference to FIGS. 1-4, an embodiment of the method may involve removing existing exterior structures 14 of the building exterior 10 (FIG. 1), placing rigid panel insulation members 16 to the building exterior 10 (FIG. 2), applying spray-on polyurethane insulation foam 18 (FIG. 3) to areas at the building exterior 10, and applying spray-on cladding 20 over the rigid panel insulation members 16 and over the spray-on polyurethane insulation foam 18. The method may further involve letting the spray-on cladding 20 cure in-place. In the example described in connection with this embodiment and FIGS. 1-4, the building exterior 10 is of a building B that is a residential home H.

[0022] With reference to FIG. 1, the step of removing any existing exterior structures 14 can be performed initially in the method of retrofitting building exteriors 10 with the insulation and cladding construction 12, and before the subsequent step of placing the rigid panel insulation members 16 to the building exterior 10. Removal of any existing exterior structures 14 may be needed in order to ready and prepare the building exterior 10 for the subsequent step of placing the rigid panel insulation members 16 thereto. Existing exterior structures 14 that are aged, obsolete, unneeded, unwanted, and / or no longer useful can be uninstalled and taken down from the building exterior 10. Depending on the particular building B—in this case the particular residential home H—the existing exterior structure 14 can differ in structure, type, and / or kind. Examples include siding parts and materials and / or fenestration (e.g., windows, doors) parts and materials, among other possibilities. Siding and a window are depicted in FIG. 1. Once removed, the condition of the underlying and now-exposed sheathing, substrate, and / or other surface—all denoted by letter S in FIG. 1—can be inspected and examined. Possible moisture intrusion and damage, mold presence, or other defects can be identified and addressed if warranted and desired. Air and water resistive barriers and wraps can be repaired or added at this step.

[0023] With reference to FIG. 2, the step of placing the rigid panel insulation members 16 to the building exterior 10 is performed after removal of any existing exterior structures 14 in the method of retrofitting building exteriors 10 with the insulation and cladding construction 12, according to this embodiment. The rigid panel insulation members 16 serve to provide a measure of insulative capabilities of the insulation and cladding construction 12. In the insulation and cladding construction 12, the rigid panel insulation members 16 constitute an interior component thereof that is enveloped by the spray-on cladding 20. The rigid panel insulation members 16 are in the form of solid and planar boards in this embodiment. In a specific example, the rigid panel insulation members 16 are composed of a foam polyisocyanurate, exhibit an insulative R-value rating of R-15, and are 2.5 inches in thickness; still, other materials, other R-value ratings, and other thickness dimensions are possible in other examples. The rigid panel insulation members 16 can be initially cut to size according to the particular building exterior 10 in which they will be placed and their particular locations. A multitude of rigid panel insulation members 16 of varying shapes and sizes can be used, as needed, and as shown in part by FIG. 2.

[0024] After placement, surface-to-surface attachment can occur between the rigid panel insulation members 16 and the surface S of the building exterior 10. The attachment can be via construction adhesives, mechanical fasteners, or via some other technique. The rigid panel insulation members 16 are placed and attached to first sections 22 and areas of the building exterior 10 and of the surface S. The first sections 22 and areas can differ per the particular building exterior 10 and per the particular surface S. In the embodiment of FIG. 2, for example, the first sections 22 and areas are established by generally flat areas 24 of the building exterior 10 and of the surface S. The generally flat areas 24 are generally planar and substantially correspond to the generally planar rigid panel insulation members 16. Where appropriate, certain less-than-flat areas can be accommodated for placement and attachment of the rigid panel insulation members 16. Overall, per an embodiment, approximately eighty percent (80%) or more of the area of the building exterior 10 and surface S subject to the insulation and cladding construction 12 can be covered by the rigid panel insulation members 16, the remaining twenty percent (20%) or less slated for coverage by the spray-on polyurethane insulation foam 18; still, in other embodiments other percentages of coverage are possible.

[0025] Referring now to FIG. 3, after placement and attachment, voids and areas lacking panels can exist such as seams 26 and gaps 28. The seams 26 can be established and can reside between adjacent and neighboring rigid panel insulation members 16, such as between side-by-side and top-and-bottom rigid panel insulation members 16. The gaps 28, on the other hand, can be established and can reside at locations challenging to reach including around fenestrations, near wall-to-roof joints, near foundation-to-wall transitions, around inner and outer corner regions, and near or around other architectural sites and details. Indeed, according to at least one embodiment, the seams 26 and / or gaps 28 can be intentionally designed in order to accommodate a coverage width of a spray gun 30 or other equipment utilized in the application of the spray-on polyurethane insulation foam 18. In this way, execution of a single-pass spray of the spray-on polyurethane insulation foam 18 via the spray gun 30 or via other equipment can be sufficient to cover the seams 26 and gaps 28 without substantial and unduly overlap of the spray-on polyurethane insulation foam 18 on the adjacent rigid panel insulation members 16; still, in other embodiments the spray-on polyurethane insulation foam 18 need not be only directed at the seams 26 and gaps 28 and could overlap the rigid panel insulation members 16. Furthermore, after placement and attachment, the rigid panel insulation members 16 can provide a surface template of sorts for the subsequently-applied spray-on polyurethane insulation foam 18. For instance, the placed and attached rigid panel insulation members 16 can provide a height, size, and / or shape template for finishing procedures of the spray-on polyurethane insulation foam 18, which is usually done via abrasion tools. The placed and attached rigid panel insulation members 16 can case and simplify such finishing procedures.

[0026] With continued reference to FIG. 3, the step of applying the spray-on polyurethane insulation foam 18 is performed after placement of the rigid panel insulation members 16 in the method of retrofitting building exteriors 10 with the insulation and cladding construction 12, according to this embodiment. With respect to the rigid panel insulation members 16, the spray-on polyurethane insulation foam 18 serves to provide another measure of insulative capabilities of the insulation and cladding construction 12. Indeed, together, the rigid panel insulation members 16 and the spray-on polyurethane insulation foam 18 provide a hybrid technique for insulating the building exterior 10. The spray-on polyurethane insulation foam 18 serves to unite and join the multitude of discrete rigid panel insulation members 16 into a larger entirety that provides an enhanced barrier to water and vapor intrusion. The spray-on polyurethane insulation foam 18 may be bonded to the rigid panel insulation members 16 where the two meet. In the insulation and cladding construction 12, the spray-on polyurethane insulation foam 18 constitutes an interior component thereof that is enveloped by the spray-on cladding 20. The spray-on polyurethane insulation foam 18 can be in the form of an isocyanate-based rigid polyurethane foam (RPUF) such as those used in certain structural and insulative applications due to their good adhesion to substrates, low density to high compression strength ratio, and high thermal insulation properties; still, other types and kinds of foams can be used including those that vary in properties.

[0027] In an embodiment, the spray-on polyurethane insulation foam 18 is sprayed and applied to second sections 32 and areas of the building exterior 10 and of the surface S via the spray gun 30 or via other equipment. The second sections 32 and areas can differ per the particular building exterior 10 and per the particular surface S, and also per the particular layout of the rigid panel insulation members 16. With respect to the first sections 22 and areas, the second sections 32 and areas can be distinct sections and areas of the building exterior 10 and of the surface S. The second sections 32 and areas can be sections and areas of the building exterior 10 and of the surface S where the rigid panel insulation members 16 are missing and are absent-that is, sections and areas subject to the insulation and cladding construction 12 in which coverage by the rigid panel insulation members 16 is lacking. In the embodiment of FIG. 3, for example, the second sections 32 and areas are established by the seams 26 and gaps 28. Sections and areas without the rigid panel insulation members 16 are hence filled-in by the spray-on polyurethane insulation foam 18. In this way, all sections and areas subject to the insulation and cladding construction 12 can exhibit insulative coverage. In other embodiments, the spray-on polyurethane insulation foam 18 is sprayed and applied to greater sections and areas than just those without the rigid panel insulation members 16. For example, the spray-on polyurethane insulation foam 18 can be sprayed and applied to all sections and areas of the building exterior 10 and of the surface S, including to the first and second sections 22, 32 and areas. Here, the spray-on polyurethane insulation foam 18 could be sprayed and applied directly over exposed surfaces of the rigid panel insulation members 16. Indeed, suitable adhesion can take place between the spray-on polyurethane insulation foam 18 and the exposed surfaces of the rigid panel insulation members 16.

[0028] With reference to FIG. 4, the step of applying the spray-on cladding 20 is performed after application of the spray-on polyurethane insulation foam 18 in the method of retrofitting building exteriors 10 with the insulation and cladding construction 12, according to this embodiment. The spray-on cladding 20 serves to unite and join the placed rigid panel insulation members 16 and the sprayed-on polyurethane insulation foam 18 together in order to establish and constitute a continuous and monolithic cladding exterior construction 34 thereover. Further, the spray-on cladding 20 and continuous and monolithic cladding exterior construction 34 serve a protective layer and a water / vapor barrier. Unlike the past approaches, the spray-on cladding 20 and continuous and monolithic cladding exterior construction 34 lack fastener part attachment to exterior building structures. The spray-on cladding 20 constitutes the exterior-most component, construction, and layer of the insulation and cladding construction 12. In FIG. 4, in effect, the spray-on cladding 20 is now the exterior of the building B and of the residential home H. The spray-on cladding 20 can be in the form of an applied spray-on polymeric (e.g., polyurea-based) cladding; still, other types and kinds of cladding could be used such as cement-based cladding like fiber reinforced plaster. The application of the spray-on cladding 20 can be via a spray gun or some other equipment.

[0029] Lastly, according to this embodiment, the step of letting the spray-on cladding 20 cure in-place is performed after application of the spray-on cladding 20 in the method of retrofitting building exteriors 10 with the insulation and cladding construction 12. The spray-on cladding 20 can cure in-place over the attached rigid panel insulation members 16 and over the sprayed-on polyurethane insulation foam 18. Whether this step is performed may be dependent upon the type of cladding employed in the insulation and cladding construction 12. When the applied spray-on polymeric cladding is used, it has been shown to cure in-place within tens of seconds to several minutes after application. Once cured, the spray-on cladding 20 can be finished in various fashions, per some embodiments, such as with differing colors, textures, surface decoration, or the like.

[0030] Turning now to FIGS. 5-9, in other embodiments the spray-on polyurethane insulation foam 18 can be in the form of a lignin-based polyurethane insulation foam. FIG. 5 presents images of certain industrial lignins (from upper left, clockwise): Kraft lignin (LignoBoost), Kraft lignin (Indulin AT), Organosolv lignin (Ethanol), and Lignosulfonate (Sulfite pulping). The lignin-based polyurethane insulation foam can have differing constituent elements in varying embodiments. In general, lignin is a polyaromatic and plant-derived biomolecule. In terms of its structure, lignin is composed of phenylpropanoid units cross-linked with aryl-ether and C—C bonds and high functional groups (e.g., aromatic ring, hydroxyl, methoxy) that endow lignin with chemical versatility for modification. FIG. 6 presents a tentative structural elucidation of pine lignin, as an example. Lignin macromolecules have a fair amount of reactive hydroxyl and minor carboxylic groups for potential formation of urethane (i.e., carbamate) groups with isocyanate.

[0031] Efforts have been made to directly replace polyols with lignin up to 30 wt % for polyurethane production. Still, certain challenges remain in the production of lignin-based RPUF. For one, the reaction between the isocyanate and lignin hydroxyl groups has been generally shown to be too slow for practical purposes and typically will not reach completion. It has been determined that this challenge can be largely resolved by chemical modification of lignin (e.g., esterification, polyhydric alcohol liquefaction, oxypropylation, and oxyalkylation, etc.) whereby increasing the amount of more reactive aliphatic hydroxyl groups and promoting the reaction between them and isocyanates. FIG. 7 depicts a lignin-isocyanate reaction. Another challenge lies in the heterogeneous and complex structure of lignin molecules. A uniform structure of the lignin fractions has proved a factor for ensuring well-defined properties in corresponding foams. FIG. 8 is a schematic depiction of lignin-based polyurethane (PU) foams obtained from different lignin sources and foam structure. In view of these challenges, the lignin-based polyurethane insulation foam has a structure-tailored and aminated lignin that replaces petroleum-derived side-B polyols in non-lignin-based polyurethane insulation foams. The structure-tailored and aminated lignin can be made based on certain hypotheses: i) fractionation of lignin with narrow range of molecular sizes and hydroxyl groups abundance before blending into polyol warrant the uniform structure of precursors for RPUF formation and enhanced performance of the accompanying final products, and ii) introduction of more reactive amino groups into lignin for the nucleophilic reaction with isocyanates than the intrinsic hydroxyl groups of lignin (i.e., the relative reaction rates of aliphatic primary amine, secondary amine, primary hydroxyl, secondary hydroxyls are 100,000, 20,000, 100, and 30, respectively).

[0032] Furthermore, native lignin hydroxyl groups (˜7 mmol / g) warrant its feasibility as components for replacing petroleum-based polyols. It has been determined that lignin-based polyurethane insulation foam can serve to increase the renewable content thereof, and can provide improved performance such as enhanced ultraviolet (UV) resistance, fire retardancy, biodegradability, and antioxidant properties thereof. The rigid structure of lignin permits its utilization as a low-cost and low-carbon hard fragment / filler with high-strength reinforcing effects for polyurethanes. Moreover, plant-derived lignin is abundant as it is removed as waste from certain pulping and biorefining industries; lignin particles are generally considered non-toxic in vitro or in vivo per certain toxicological assessments; and the biodegradability of lignin provides a degree of environmental sustainability.

[0033] In an embodiment, the lignin-based polyurethane insulation foam can be composed of as much as 20% to 25% lignin polyols. The Kraft lignin Indulin AT can be fractionated into structurally uniform lignins and more reactive amine groups can be introduced into lignin fractions to replace petrochemicals for production, as an example.

[0034] The Kraft lignin Indulin AT is a highly purified, unsulfonated, and highly functionalized carboxylic acid, aliphatic and aromatic hydroxyl groups raw kraft lignin. It can be fractionated to obtain structure-tailored lignins. The Kraft lignin Indulin AT is pine-derived, and is rich in guaiacyl units (“G” in FIG. 6) that allows relative more sites for the amination reaction. Per co-solvent fractionation methods, lignins with low (<1,000 Da), medium (1,000-4,000 Da), and high (>4,000 Da) weight-average molecular weights will be fractionated for amination. Subsequently, secondary aliphatic amine groups can be introduced to the fractionated lignins and the non-fractionated lignins using Mannich reactions. FIG. 9 is a schematic depiction of a Mannich reaction highlighting amination of lignin subunits. After reaction, the aminated lignin can be purified by rotary evaporation to remove unreacted organic solvent, dialysis to remove unreacted chemicals, and vacuum dried for structural and properties characterization and RPUF synthesis. The introduction of secondary amine groups can significantly increase the reactivity of lignin with isocyanates.

[0035] The table below presents compositions of basic mixtures and varying amounts of isocyanate indices, per an embodiment, for the fabrication of high-density RPUF using aminated and non-aminated lignin fractions:AmountComponentFunction(g)Lignin / aminated ligninSustainable polyols1GlycerolSolvent for lignin0.5EJ300 (epoxide)Solvent for lignin1PEG 400Solvent for lignin—PPG triolChain extender2.5HydrochlorofluoroolefinsNon-ozone depleting blowing agent0.17DABCO NE1070Catalyst for gelling0.08DABCO NE300Catalyst for blowing0.08DABCO DC2525Surfactant (improve uniformity)0.04pMDI (GreenAdduct13)Isocyanate3.1-4.7

[0036] Furthermore, in variations to embodiments herein, other designs, constructions, and components of the insulation and cladding construction 12 could include a drainage plane outfitted between the underlying surface and the rigid panel insulation members 16 and spray-on polyurethane insulation foam 18. Moreover, simulations have shown that overall an approximately 20% energy savings can be had for a residential home similar to that described herein via employment of the insulation and cladding construction 12; still, other energy savings may be observed in other examples of the insulation and cladding construction.

[0037] In general, while a multitude of embodiments have been depicted and described with a multitude of components and steps in each embodiment, in alternative embodiments of the method of retrofitting building exteriors with the insulation and cladding construction the components and steps of various embodiments could be intermixed, combined, and / or exchanged for one another. In other words, components described in connection with a particular embodiment are not necessarily exclusive to that particular embodiment.

[0038] As used herein, the terms “general” and “generally” and “substantially” are intended to account for the inherent degree of variance and imprecision that is often attributed to, and often accompanies, any design and manufacturing process, including engineering tolerances-and without deviation from the relevant functionality and intended outcome-such that mathematical precision and exactitude is not implied and, in some instances, is not possible. In other instances, the terms “general” and “generally” and “substantially” are intended to represent the inherent degree of uncertainty that is often attributed to any quantitative comparison, value, and measurement calculation, or other representation.

[0039] It is to be understood that the foregoing is a description of one or more aspects of the disclosure. The disclosure is not limited to the particular embodiment(s) disclosed herein, but rather is defined solely by the claims below. Furthermore, the statements contained in the foregoing description relate to particular embodiments and are not to be construed as limitations on the scope of the disclosure or on the definition of terms used in the claims, except where a term or phrase is expressly defined above. Various other embodiments and various changes and modifications to the disclosed embodiment(s) will become apparent to those skilled in the art. All such other embodiments, changes, and modifications are intended to come within the scope of the appended claims.

[0040] As used in this specification and claims, the terms “e.g.,”“for example,”“for instance,”“such as,” and “like,” and the verbs “comprising,”“having,”“including,” and their other verb forms, when used in conjunction with a listing of one or more components or other items, are each to be construed as open-ended, meaning that the listing is not to be considered as excluding other, additional components or items. Other terms are to be construed using their broadest reasonable meaning unless they are used in a context that requires a different interpretation.

[0041] Those of skill in the art will understand that modifications (additions and / or removals) of various components of the substances, formulations, apparatuses, methods, systems, and embodiments described herein may be made without departing from the full scope and spirit of the present disclosure, which encompass such modifications and any and all equivalents thereof.

Examples

Embodiment Construction

[0018]Referring generally to the drawings, embodiments of a process and method of retrofitting building exteriors 10 with an insulation and cladding construction 12 are depicted in the figures and described herein. The method and construction furnishes a continuous and monolithic exterior insulation and cladding layer and envelop over buildings, and is a hybrid system in the sense that it combines insulative paneling and insulative foam spraying together via a cladding thereover, effectively leveraging the benefits of both insulation capabilities. Compared to past approaches, a simplified and faster installation procedure is provided with the process and method of retrofitting building exteriors 10 as set forth herein, as well as a minimization of labor and material costs. Moreover, the process and method herein can provide a reduction in disturbances to use and occupancy of the subject building. Furthermore, unlike the past approaches, fastener part attachment to exterior building ...

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 530,281, with a filing date of Aug. 2, 2023, the contents of which are hereby incorporated by reference in their entirety.TECHNICAL FIELD

[0002] The present disclosure relates generally to retrofitted building exteriors and, more particularly, to processes and procedures for retrofitting building exteriors with insulation and cladding constructions.BACKGROUND

[0003] Retrofitting existing homes for increased energy efficiency can involve augmenting insulation, installing high performance fenestrations, and sealing homes with air and vapor barriers. Exterior insulation, in particular, helps lower energy use in heating, ventilation, and air conditioning (HVAC) of homes, and helps with potential moisture issues encountered in walls. Previous exterior insulation approaches typically require the creation of an external installation for siding attachment that transmits loads exerted at the exterior back to a structure of the associated home. Common practices employ fastener part attachment of furring strips directly to each vertical stud of the home. In some cases, this is called-for in order to satisfy siding manufacturers' requirements and / or to comply with certain applicable international residential codes. But this approach and practice has proven costly and overly burdensome for installers due to—among other drawbacks—the time-consuming verification of fastener part attachment to ensure proper installation.SUMMARY

[0004] In an embodiment, a method of retrofitting a building exterior with an insulation and cladding construction may involve multiple steps. One step may involve the placement of rigid panel insulation members to first sections or more sections of the building exterior. Another step may involve the application of spray-on polyurethane insulation foam to second sections or more sections of the building exterior. Yet another step may involve the application of spray-on cladding over the already-placed rigid panel insulation members, and the application of spray-on cladding over the already-applied spray-on polyurethane insulation foam. The applied spray-on cladding resides at the first and second sections or at more sections of the building exterior. The applied spray-on cladding serves to join the already-placed rigid panel insulation members and the already-applied spray-on polyurethane insulation foam, and thereby establishes a continuous and monolithic cladding exterior construction.

[0005] In an embodiment, a method of retrofitting a building exterior with an insulation and cladding construction may involve multiple steps. One step may involve the attachment of rigid panel insulation members to generally flat areas of the building exterior. Another step may involve spraying-on polyurethane insulation foam to seam areas or more areas at the building exterior. The seam areas being established between adjacent and already-attached rigid panel insulation members. Yet another step may involve spraying-on cladding over the already-attached rigid panel insulation members, and spraying-on cladding over the already sprayed-on polyurethane insulation foam. The sprayed-on cladding constitutes a monolithic cladding exterior construction of the building.

[0006] In an embodiment, a method of retrofitting a building exterior with an insulation and cladding construction may involve multiple steps. One step may involve removing existing exterior structures at the building exterior. Another step may involve the placement of rigid panel insulation members to generally flat areas of the building exterior. Yet another step may involve spraying-on polyurethane insulation foam to some areas or more areas of the building exterior where the already-placed rigid panel insulation members are not present and are hence absent. And another step may involve spraying-on cladding over the already-placed rigid panel insulation members, and spraying-on cladding over the already sprayed-on polyurethane insulation foam. The sprayed-on cladding serves to join the already-placed rigid panel insulation members and the already sprayed-on polyurethane insulation foam together. Further, the sprayed-on cladding cures in-place over the already-placed rigid panel insulation members and over the already sprayed-on polyurethane insulation foam.

[0007] Further scope of applicability of the present disclosure will become apparent from the detailed description given hereinafter. But it should be understood that the detailed description and specific examples, while indicating exemplary embodiments of the disclosure, are given by way of illustration only, since various changes and modifications within the spirit and scope of the disclosure will become apparent to those skilled in the art from this detailed description.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The present disclosure will become more fully understood from the detailed description given below and the accompanying drawings, which are given by way of illustration only, and do not limit the present disclosure, and wherein:

[0009] FIG. 1 is a schematic depiction of a step involved in an embodiment of a method of retrofitting a building exterior with an insulation and cladding construction;

[0010] FIG. 2 is a schematic depiction of another step involved in the method of retrofitting a building exterior;

[0011] FIG. 3 is a schematic depiction of another step involved in the method of retrofitting a building exterior;

[0012] FIG. 4 is a schematic depiction of another step involved in the method of retrofitting a building exterior;

[0013] FIG. 5 presents images of certain industrial lignins (from upper left, clockwise): Kraft lignin (LignoBoost), Kraft lignin (Indulin AT), Organosolv lignin (Ethanol), and Lignosulfonate (Sulfite pulping);

[0014] FIG. 6 presents a tentative structural elucidation of pine lignin;

[0015] FIG. 7 depicts a lignin-isocyanate reaction;

[0016] FIG. 8 is a schematic depiction of lignin-based polyurethane (PU) foams obtained from different lignin sources and foam structure; and

[0017] FIG. 9 is a schematic depiction of a Mannich reaction highlighting amination of lignin subunits.DETAILED DESCRIPTION

[0018] Referring generally to the drawings, embodiments of a process and method of retrofitting building exteriors 10 with an insulation and cladding construction 12 are depicted in the figures and described herein. The method and construction furnishes a continuous and monolithic exterior insulation and cladding layer and envelop over buildings, and is a hybrid system in the sense that it combines insulative paneling and insulative foam spraying together via a cladding thereover, effectively leveraging the benefits of both insulation capabilities. Compared to past approaches, a simplified and faster installation procedure is provided with the process and method of retrofitting building exteriors 10 as set forth herein, as well as a minimization of labor and material costs. Moreover, the process and method herein can provide a reduction in disturbances to use and occupancy of the subject building. Furthermore, unlike the past approaches, fastener part attachment to exterior building structures-which often requires the transfer of loads to existing building structures (e.g., via furring strips to vertical studs) and is often overly burdensome in practice-is unneeded with the employment of the process and method of retrofitting building exteriors 10 set forth herein. And unlike adding insulation within wall cavities, another way to augment insulation and which usually requires drywall removal, the process and method herein does not cause drywall disruption.

[0019] Yet further, an overall more efficient and effective insulation and cladding exterior construction is depicted and described herein that can replace and improve obsolete building exteriors. The method and construction can provide enhanced structural integrity and durability at building exteriors, an increased insulative performance and R-value rating, an improved barrier to water and vapor intrusion, a more resilient weathering and longevity, and / or a greater ability to withstand weather hazards such as windstorms and tornadoes and hurricanes. Still, a particular embodiment of the process and method of retrofitting building exteriors 10 with the insulation and cladding construction 12 may exhibit only one, all, or a combination of, the advancements set forth herein, none of the advancements, or yet other advancements unmentioned.

[0020] Further, as used herein, the term “building” is intended to have an expansive meaning that encompasses commercial and non-commercial buildings, residential and non-residential buildings, single-and multi-family dwellings and housing, as well as other types of structures.

[0021] The method of retrofitting building exteriors 10 with the insulation and cladding construction 12 may have varied steps according to different embodiments, and may have more, less, and / or different steps than those presented herein. Indeed, the steps of the method may at least partly be dictated by the building subject to retrofitting and the desired and intended performance of the insulation and cladding exterior construction 12. The steps need not necessarily be performed in the particular order described and depicted. With general reference to FIGS. 1-4, an embodiment of the method may involve removing existing exterior structures 14 of the building exterior 10 (FIG. 1), placing rigid panel insulation members 16 to the building exterior 10 (FIG. 2), applying spray-on polyurethane insulation foam 18 (FIG. 3) to areas at the building exterior 10, and applying spray-on cladding 20 over the rigid panel insulation members 16 and over the spray-on polyurethane insulation foam 18. The method may further involve letting the spray-on cladding 20 cure in-place. In the example described in connection with this embodiment and FIGS. 1-4, the building exterior 10 is of a building B that is a residential home H.

[0022] With reference to FIG. 1, the step of removing any existing exterior structures 14 can be performed initially in the method of retrofitting building exteriors 10 with the insulation and cladding construction 12, and before the subsequent step of placing the rigid panel insulation members 16 to the building exterior 10. Removal of any existing exterior structures 14 may be needed in order to ready and prepare the building exterior 10 for the subsequent step of placing the rigid panel insulation members 16 thereto. Existing exterior structures 14 that are aged, obsolete, unneeded, unwanted, and / or no longer useful can be uninstalled and taken down from the building exterior 10. Depending on the particular building B—in this case the particular residential home H—the existing exterior structure 14 can differ in structure, type, and / or kind. Examples include siding parts and materials and / or fenestration (e.g., windows, doors) parts and materials, among other possibilities. Siding and a window are depicted in FIG. 1. Once removed, the condition of the underlying and now-exposed sheathing, substrate, and / or other surface—all denoted by letter S in FIG. 1—can be inspected and examined. Possible moisture intrusion and damage, mold presence, or other defects can be identified and addressed if warranted and desired. Air and water resistive barriers and wraps can be repaired or added at this step.

[0023] With reference to FIG. 2, the step of placing the rigid panel insulation members 16 to the building exterior 10 is performed after removal of any existing exterior structures 14 in the method of retrofitting building exteriors 10 with the insulation and cladding construction 12, according to this embodiment. The rigid panel insulation members 16 serve to provide a measure of insulative capabilities of the insulation and cladding construction 12. In the insulation and cladding construction 12, the rigid panel insulation members 16 constitute an interior component thereof that is enveloped by the spray-on cladding 20. The rigid panel insulation members 16 are in the form of solid and planar boards in this embodiment. In a specific example, the rigid panel insulation members 16 are composed of a foam polyisocyanurate, exhibit an insulative R-value rating of R-15, and are 2.5 inches in thickness; still, other materials, other R-value ratings, and other thickness dimensions are possible in other examples. The rigid panel insulation members 16 can be initially cut to size according to the particular building exterior 10 in which they will be placed and their particular locations. A multitude of rigid panel insulation members 16 of varying shapes and sizes can be used, as needed, and as shown in part by FIG. 2.

[0024] After placement, surface-to-surface attachment can occur between the rigid panel insulation members 16 and the surface S of the building exterior 10. The attachment can be via construction adhesives, mechanical fasteners, or via some other technique. The rigid panel insulation members 16 are placed and attached to first sections 22 and areas of the building exterior 10 and of the surface S. The first sections 22 and areas can differ per the particular building exterior 10 and per the particular surface S. In the embodiment of FIG. 2, for example, the first sections 22 and areas are established by generally flat areas 24 of the building exterior 10 and of the surface S. The generally flat areas 24 are generally planar and substantially correspond to the generally planar rigid panel insulation members 16. Where appropriate, certain less-than-flat areas can be accommodated for placement and attachment of the rigid panel insulation members 16. Overall, per an embodiment, approximately eighty percent (80%) or more of the area of the building exterior 10 and surface S subject to the insulation and cladding construction 12 can be covered by the rigid panel insulation members 16, the remaining twenty percent (20%) or less slated for coverage by the spray-on polyurethane insulation foam 18; still, in other embodiments other percentages of coverage are possible.

[0025] Referring now to FIG. 3, after placement and attachment, voids and areas lacking panels can exist such as seams 26 and gaps 28. The seams 26 can be established and can reside between adjacent and neighboring rigid panel insulation members 16, such as between side-by-side and top-and-bottom rigid panel insulation members 16. The gaps 28, on the other hand, can be established and can reside at locations challenging to reach including around fenestrations, near wall-to-roof joints, near foundation-to-wall transitions, around inner and outer corner regions, and near or around other architectural sites and details. Indeed, according to at least one embodiment, the seams 26 and / or gaps 28 can be intentionally designed in order to accommodate a coverage width of a spray gun 30 or other equipment utilized in the application of the spray-on polyurethane insulation foam 18. In this way, execution of a single-pass spray of the spray-on polyurethane insulation foam 18 via the spray gun 30 or via other equipment can be sufficient to cover the seams 26 and gaps 28 without substantial and unduly overlap of the spray-on polyurethane insulation foam 18 on the adjacent rigid panel insulation members 16; still, in other embodiments the spray-on polyurethane insulation foam 18 need not be only directed at the seams 26 and gaps 28 and could overlap the rigid panel insulation members 16. Furthermore, after placement and attachment, the rigid panel insulation members 16 can provide a surface template of sorts for the subsequently-applied spray-on polyurethane insulation foam 18. For instance, the placed and attached rigid panel insulation members 16 can provide a height, size, and / or shape template for finishing procedures of the spray-on polyurethane insulation foam 18, which is usually done via abrasion tools. The placed and attached rigid panel insulation members 16 can case and simplify such finishing procedures.

[0026] With continued reference to FIG. 3, the step of applying the spray-on polyurethane insulation foam 18 is performed after placement of the rigid panel insulation members 16 in the method of retrofitting building exteriors 10 with the insulation and cladding construction 12, according to this embodiment. With respect to the rigid panel insulation members 16, the spray-on polyurethane insulation foam 18 serves to provide another measure of insulative capabilities of the insulation and cladding construction 12. Indeed, together, the rigid panel insulation members 16 and the spray-on polyurethane insulation foam 18 provide a hybrid technique for insulating the building exterior 10. The spray-on polyurethane insulation foam 18 serves to unite and join the multitude of discrete rigid panel insulation members 16 into a larger entirety that provides an enhanced barrier to water and vapor intrusion. The spray-on polyurethane insulation foam 18 may be bonded to the rigid panel insulation members 16 where the two meet. In the insulation and cladding construction 12, the spray-on polyurethane insulation foam 18 constitutes an interior component thereof that is enveloped by the spray-on cladding 20. The spray-on polyurethane insulation foam 18 can be in the form of an isocyanate-based rigid polyurethane foam (RPUF) such as those used in certain structural and insulative applications due to their good adhesion to substrates, low density to high compression strength ratio, and high thermal insulation properties; still, other types and kinds of foams can be used including those that vary in properties.

[0027] In an embodiment, the spray-on polyurethane insulation foam 18 is sprayed and applied to second sections 32 and areas of the building exterior 10 and of the surface S via the spray gun 30 or via other equipment. The second sections 32 and areas can differ per the particular building exterior 10 and per the particular surface S, and also per the particular layout of the rigid panel insulation members 16. With respect to the first sections 22 and areas, the second sections 32 and areas can be distinct sections and areas of the building exterior 10 and of the surface S. The second sections 32 and areas can be sections and areas of the building exterior 10 and of the surface S where the rigid panel insulation members 16 are missing and are absent-that is, sections and areas subject to the insulation and cladding construction 12 in which coverage by the rigid panel insulation members 16 is lacking. In the embodiment of FIG. 3, for example, the second sections 32 and areas are established by the seams 26 and gaps 28. Sections and areas without the rigid panel insulation members 16 are hence filled-in by the spray-on polyurethane insulation foam 18. In this way, all sections and areas subject to the insulation and cladding construction 12 can exhibit insulative coverage. In other embodiments, the spray-on polyurethane insulation foam 18 is sprayed and applied to greater sections and areas than just those without the rigid panel insulation members 16. For example, the spray-on polyurethane insulation foam 18 can be sprayed and applied to all sections and areas of the building exterior 10 and of the surface S, including to the first and second sections 22, 32 and areas. Here, the spray-on polyurethane insulation foam 18 could be sprayed and applied directly over exposed surfaces of the rigid panel insulation members 16. Indeed, suitable adhesion can take place between the spray-on polyurethane insulation foam 18 and the exposed surfaces of the rigid panel insulation members 16.

[0028] With reference to FIG. 4, the step of applying the spray-on cladding 20 is performed after application of the spray-on polyurethane insulation foam 18 in the method of retrofitting building exteriors 10 with the insulation and cladding construction 12, according to this embodiment. The spray-on cladding 20 serves to unite and join the placed rigid panel insulation members 16 and the sprayed-on polyurethane insulation foam 18 together in order to establish and constitute a continuous and monolithic cladding exterior construction 34 thereover. Further, the spray-on cladding 20 and continuous and monolithic cladding exterior construction 34 serve a protective layer and a water / vapor barrier. Unlike the past approaches, the spray-on cladding 20 and continuous and monolithic cladding exterior construction 34 lack fastener part attachment to exterior building structures. The spray-on cladding 20 constitutes the exterior-most component, construction, and layer of the insulation and cladding construction 12. In FIG. 4, in effect, the spray-on cladding 20 is now the exterior of the building B and of the residential home H. The spray-on cladding 20 can be in the form of an applied spray-on polymeric (e.g., polyurea-based) cladding; still, other types and kinds of cladding could be used such as cement-based cladding like fiber reinforced plaster. The application of the spray-on cladding 20 can be via a spray gun or some other equipment.

[0029] Lastly, according to this embodiment, the step of letting the spray-on cladding 20 cure in-place is performed after application of the spray-on cladding 20 in the method of retrofitting building exteriors 10 with the insulation and cladding construction 12. The spray-on cladding 20 can cure in-place over the attached rigid panel insulation members 16 and over the sprayed-on polyurethane insulation foam 18. Whether this step is performed may be dependent upon the type of cladding employed in the insulation and cladding construction 12. When the applied spray-on polymeric cladding is used, it has been shown to cure in-place within tens of seconds to several minutes after application. Once cured, the spray-on cladding 20 can be finished in various fashions, per some embodiments, such as with differing colors, textures, surface decoration, or the like.

[0030] Turning now to FIGS. 5-9, in other embodiments the spray-on polyurethane insulation foam 18 can be in the form of a lignin-based polyurethane insulation foam. FIG. 5 presents images of certain industrial lignins (from upper left, clockwise): Kraft lignin (LignoBoost), Kraft lignin (Indulin AT), Organosolv lignin (Ethanol), and Lignosulfonate (Sulfite pulping). The lignin-based polyurethane insulation foam can have differing constituent elements in varying embodiments. In general, lignin is a polyaromatic and plant-derived biomolecule. In terms of its structure, lignin is composed of phenylpropanoid units cross-linked with aryl-ether and C—C bonds and high functional groups (e.g., aromatic ring, hydroxyl, methoxy) that endow lignin with chemical versatility for modification. FIG. 6 presents a tentative structural elucidation of pine lignin, as an example. Lignin macromolecules have a fair amount of reactive hydroxyl and minor carboxylic groups for potential formation of urethane (i.e., carbamate) groups with isocyanate.

[0031] Efforts have been made to directly replace polyols with lignin up to 30 wt % for polyurethane production. Still, certain challenges remain in the production of lignin-based RPUF. For one, the reaction between the isocyanate and lignin hydroxyl groups has been generally shown to be too slow for practical purposes and typically will not reach completion. It has been determined that this challenge can be largely resolved by chemical modification of lignin (e.g., esterification, polyhydric alcohol liquefaction, oxypropylation, and oxyalkylation, etc.) whereby increasing the amount of more reactive aliphatic hydroxyl groups and promoting the reaction between them and isocyanates. FIG. 7 depicts a lignin-isocyanate reaction. Another challenge lies in the heterogeneous and complex structure of lignin molecules. A uniform structure of the lignin fractions has proved a factor for ensuring well-defined properties in corresponding foams. FIG. 8 is a schematic depiction of lignin-based polyurethane (PU) foams obtained from different lignin sources and foam structure. In view of these challenges, the lignin-based polyurethane insulation foam has a structure-tailored and aminated lignin that replaces petroleum-derived side-B polyols in non-lignin-based polyurethane insulation foams. The structure-tailored and aminated lignin can be made based on certain hypotheses: i) fractionation of lignin with narrow range of molecular sizes and hydroxyl groups abundance before blending into polyol warrant the uniform structure of precursors for RPUF formation and enhanced performance of the accompanying final products, and ii) introduction of more reactive amino groups into lignin for the nucleophilic reaction with isocyanates than the intrinsic hydroxyl groups of lignin (i.e., the relative reaction rates of aliphatic primary amine, secondary amine, primary hydroxyl, secondary hydroxyls are 100,000, 20,000, 100, and 30, respectively).

[0032] Furthermore, native lignin hydroxyl groups (˜7 mmol / g) warrant its feasibility as components for replacing petroleum-based polyols. It has been determined that lignin-based polyurethane insulation foam can serve to increase the renewable content thereof, and can provide improved performance such as enhanced ultraviolet (UV) resistance, fire retardancy, biodegradability, and antioxidant properties thereof. The rigid structure of lignin permits its utilization as a low-cost and low-carbon hard fragment / filler with high-strength reinforcing effects for polyurethanes. Moreover, plant-derived lignin is abundant as it is removed as waste from certain pulping and biorefining industries; lignin particles are generally considered non-toxic in vitro or in vivo per certain toxicological assessments; and the biodegradability of lignin provides a degree of environmental sustainability.

[0033] In an embodiment, the lignin-based polyurethane insulation foam can be composed of as much as 20% to 25% lignin polyols. The Kraft lignin Indulin AT can be fractionated into structurally uniform lignins and more reactive amine groups can be introduced into lignin fractions to replace petrochemicals for production, as an example.

[0034] The Kraft lignin Indulin AT is a highly purified, unsulfonated, and highly functionalized carboxylic acid, aliphatic and aromatic hydroxyl groups raw kraft lignin. It can be fractionated to obtain structure-tailored lignins. The Kraft lignin Indulin AT is pine-derived, and is rich in guaiacyl units (“G” in FIG. 6) that allows relative more sites for the amination reaction. Per co-solvent fractionation methods, lignins with low (<1,000 Da), medium (1,000-4,000 Da), and high (>4,000 Da) weight-average molecular weights will be fractionated for amination. Subsequently, secondary aliphatic amine groups can be introduced to the fractionated lignins and the non-fractionated lignins using Mannich reactions. FIG. 9 is a schematic depiction of a Mannich reaction highlighting amination of lignin subunits. After reaction, the aminated lignin can be purified by rotary evaporation to remove unreacted organic solvent, dialysis to remove unreacted chemicals, and vacuum dried for structural and properties characterization and RPUF synthesis. The introduction of secondary amine groups can significantly increase the reactivity of lignin with isocyanates.

[0035] The table below presents compositions of basic mixtures and varying amounts of isocyanate indices, per an embodiment, for the fabrication of high-density RPUF using aminated and non-aminated lignin fractions:AmountComponentFunction(g)Lignin / aminated ligninSustainable polyols1GlycerolSolvent for lignin0.5EJ300 (epoxide)Solvent for lignin1PEG 400Solvent for lignin—PPG triolChain extender2.5HydrochlorofluoroolefinsNon-ozone depleting blowing agent0.17DABCO NE1070Catalyst for gelling0.08DABCO NE300Catalyst for blowing0.08DABCO DC2525Surfactant (improve uniformity)0.04pMDI (GreenAdduct13)Isocyanate3.1-4.7

[0036] Furthermore, in variations to embodiments herein, other designs, constructions, and components of the insulation and cladding construction 12 could include a drainage plane outfitted between the underlying surface and the rigid panel insulation members 16 and spray-on polyurethane insulation foam 18. Moreover, simulations have shown that overall an approximately 20% energy savings can be had for a residential home similar to that described herein via employment of the insulation and cladding construction 12; still, other energy savings may be observed in other examples of the insulation and cladding construction.

[0037] In general, while a multitude of embodiments have been depicted and described with a multitude of components and steps in each embodiment, in alternative embodiments of the method of retrofitting building exteriors with the insulation and cladding construction the components and steps of various embodiments could be intermixed, combined, and / or exchanged for one another. In other words, components described in connection with a particular embodiment are not necessarily exclusive to that particular embodiment.

[0038] As used herein, the terms “general” and “generally” and “substantially” are intended to account for the inherent degree of variance and imprecision that is often attributed to, and often accompanies, any design and manufacturing process, including engineering tolerances-and without deviation from the relevant functionality and intended outcome-such that mathematical precision and exactitude is not implied and, in some instances, is not possible. In other instances, the terms “general” and “generally” and “substantially” are intended to represent the inherent degree of uncertainty that is often attributed to any quantitative comparison, value, and measurement calculation, or other representation.

[0039] It is to be understood that the foregoing is a description of one or more aspects of the disclosure. The disclosure is not limited to the particular embodiment(s) disclosed herein, but rather is defined solely by the claims below. Furthermore, the statements contained in the foregoing description relate to particular embodiments and are not to be construed as limitations on the scope of the disclosure or on the definition of terms used in the claims, except where a term or phrase is expressly defined above. Various other embodiments and various changes and modifications to the disclosed embodiment(s) will become apparent to those skilled in the art. All such other embodiments, changes, and modifications are intended to come within the scope of the appended claims.

[0040] As used in this specification and claims, the terms “e.g.,”“for example,”“for instance,”“such as,” and “like,” and the verbs “comprising,”“having,”“including,” and their other verb forms, when used in conjunction with a listing of one or more components or other items, are each to be construed as open-ended, meaning that the listing is not to be considered as excluding other, additional components or items. Other terms are to be construed using their broadest reasonable meaning unless they are used in a context that requires a different interpretation.

[0041] Those of skill in the art will understand that modifications (additions and / or removals) of various components of the substances, formulations, apparatuses, methods, systems, and embodiments described herein may be made without departing from the full scope and spirit of the present disclosure, which encompass such modifications and any and all equivalents thereof.

Examples

Embodiment Construction

[0018]Referring generally to the drawings, embodiments of a process and method of retrofitting building exteriors 10 with an insulation and cladding construction 12 are depicted in the figures and described herein. The method and construction furnishes a continuous and monolithic exterior insulation and cladding layer and envelop over buildings, and is a hybrid system in the sense that it combines insulative paneling and insulative foam spraying together via a cladding thereover, effectively leveraging the benefits of both insulation capabilities. Compared to past approaches, a simplified and faster installation procedure is provided with the process and method of retrofitting building exteriors 10 as set forth herein, as well as a minimization of labor and material costs. Moreover, the process and method herein can provide a reduction in disturbances to use and occupancy of the subject building. Furthermore, unlike the past approaches, fastener part attachment to exterior building ...

Claims

1. A method of retrofitting a building exterior with an insulation and cladding construction, the method comprising:placing rigid panel insulation members to at least first sections of the building exterior;applying spray-on polyurethane insulation foam to at least second sections of the building exterior; andapplying spray-on cladding over said placed rigid panel insulation members and over said applied spray-on polyurethane insulation foam at said at least first and second sections of the building exterior, wherein said applied spray-on cladding joins said placed rigid panel insulation members and said applied spray-on polyurethane insulation foam and establishes a continuous and monolithic cladding exterior construction thereover.

2. The method of retrofitting the building exterior as set forth in claim 1, further comprising removing existing exterior structures at the building exterior before the step of placing rigid panel insulation members to said at least first sections of the building exterior.

3. The method of retrofitting the building exterior as set forth in claim 1, further comprising attaching said placed rigid panel insulation members to said at least first sections of the building exterior, and wherein said at least first sections of the building exterior comprises generally flat areas of the building exterior.

4. The method of retrofitting the building exterior as set forth in claim 1, wherein said at least second sections of the building exterior comprises seams established between said placed rigid panel insulation members at the building exterior, gaps established between said placed rigid panel insulation members and fenestrations of the building exterior, or both seams established between said placed rigid panel insulation members at the building exterior and gaps established between said placed rigid panel insulation members and fenestrations of the building exterior.

5. The method of retrofitting the building exterior as set forth in claim 1, wherein the step of applying said spray-on polyurethane insulation foam comprises applying said spray-on polyurethane insulation foam over said placed rigid panel insulation members at said at least first sections of the building exterior.

6. The method of retrofitting the building exterior as set forth in claim 1, wherein the step of applying said spray-on polyurethane insulation foam comprises applying said spray-on polyurethane insulation foam to all sections of the building exterior.

7. The method of retrofitting the building exterior as set forth in claim 1, wherein, after application, said applied spray-on cladding cures in-place over said placed rigid panel insulation members and over said applied spray-on polyurethane insulation foam.

8. The method of retrofitting the building exterior as set forth in claim 1, wherein said applied spray-on cladding is an applied spray-on polymeric cladding.

9. The method of retrofitting the building exterior as set forth in claim 1, wherein said applied spray-on polyurethane insulation foam is an applied spray-on lignin-based polyurethane insulation foam.

10. The method of retrofitting the building exterior as set forth in claim 1, wherein said continuous and monolithic cladding exterior construction lacks fastener part attachment to a structure of the building.

11. A method of retrofitting a building exterior with an insulation and cladding construction, the method comprising:attaching rigid panel insulation members to generally flat areas of the building exterior;spraying-on polyurethane insulation foam to at least seam areas established between adjacent attached rigid panel insulation members at the building exterior; andspraying-on cladding over said attached rigid panel insulation members and over said sprayed-on polyurethane insulation foam, wherein said sprayed-on cladding constitutes a monolithic cladding exterior construction of the building.

12. The method of retrofitting the building exterior as set forth in claim 11, further comprising removing existing exterior structures at the building exterior before the step of attaching rigid panel insulation members to said generally flat areas of the building exterior.

13. The method of retrofitting the building exterior as set forth in claim 11, wherein said sprayed-on cladding joins said attached rigid panel insulation members and said sprayed-on polyurethane insulation foam together to constitute said monolithic cladding exterior construction of the building.

14. The method of retrofitting the building exterior as set forth in claim 11, further comprising spraying-on polyurethane insulation foam to gap areas established between said attached rigid panel insulation members and fenestrations of the building exterior.

15. The method of retrofitting the building exterior as set forth in claim 11, wherein the step of spraying-on polyurethane insulation foam comprises spraying-on polyurethane insulation foam to areas of said attached rigid panel insulation members.

16. The method of retrofitting the building exterior as set forth in claim 11, wherein, after application, said sprayed-on cladding cures in-place over said attached rigid panel insulation members and over said sprayed-on polyurethane insulation foam.

17. The method of retrofitting the building exterior as set forth in claim 11, wherein said sprayed-on cladding is a sprayed-on polymeric cladding.

18. The method of retrofitting the building exterior as set forth in claim 11, wherein said applied spray-on polyurethane insulation foam is an applied spray-on lignin-based polyurethane insulation foam.

19. A method of retrofitting a building exterior with an insulation and cladding construction, the method comprising:removing existing exterior structures at the building exterior;placing rigid panel insulation members to generally flat areas of the building exterior;spraying-on polyurethane insulation foam to at least some areas of the building exterior where said placed rigid panel insulation members are absent; andspraying-on cladding over said placed rigid panel insulation members and over said sprayed-on polyurethane insulation foam, wherein said sprayed-on cladding joins said placed rigid panel insulation members and said sprayed-on polyurethane insulation foam together, and wherein said sprayed-on cladding cures in-place over said placed rigid panel insulation members and over said sprayed-on polyurethane insulation foam.

20. The method of retrofitting the building exterior as set forth in claim 19, wherein said sprayed-on cladding constitutes an exterior-most construction of the building exterior, and said sprayed-on cladding lacks fastener part attachment to a structure of the building.

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