Foam Wall Structure Polyiso Board Spray Foam Insulation
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Solution Overview
Problem
Current insulated wall panel solutions, such as pre-fabricated panels and Structural Insulated Panels (SIPs), face challenges in meeting strict insulation requirements while being cost-effective and labor-efficient, with issues like air intrusion, mold growth, and inconsistent performance due to the use of fiberglass and expanded polystyrene foam.
Innovation Solution
A foam wall structure comprising a frame with a polyiso board and a foam layer, where the foam is deposited within the frame to expand and adhere to the polyiso board, providing improved thermal insulation and structural stability without the need for additional materials like OSB boards, thus reducing installation complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pre-fabricated wall panels with fiberglass insulation are used, then installation is simplified, but air intrusion and mold growth occur due to fiberglass not being an air barrier
Solution Approach 1:
The patent combines polyiso board insulation with spray foam material to create a composite insulation system. The polyiso board provides high R-value thermal insulation, while the spray foam material acts as an air barrier that seals gaps and prevents air intrusion, thereby eliminating mold growth issues while maintaining installation simplicity
Solution Approach 2:
The patent changes the physical state and application method of the insulation material by using spray foam that expands after application. This transformation allows the material to fill cavities completely, create seamless air barriers, and adhere to surfaces, thereby preventing air intrusion while maintaining ease of installation through a single-step process
2Strength
If SIPs with EPS foam insulation are used, then structural integrity is improved, but thermal performance is insufficient with only R-4 per inch
Solution Approach 1:
The patent creates a composite wall structure combining polyiso board with high R-value properties and spray foam material. This composite system achieves superior thermal performance (exceeding R-4 per inch) while the spray foam provides structural bonding and integrity, replacing the need for traditional SIP construction
Solution Approach 2:
The patent applies different materials with optimized properties to different regions: polyiso board is used for high R-value thermal insulation where heat transfer occurs, while spray foam is applied in cavities and at joints where structural bonding and air sealing are critical, thereby achieving both high thermal performance and structural integrity
3Reliability
If additional materials like OSB boards and house wrap are used, then wall completion is achieved, but construction duration is extended and scheduling conflicts increase
Solution Approach 1:
The patent merges multiple functions into a single insulation system: the polyiso board provides thermal insulation, the spray foam material provides air sealing and structural bonding, eliminating the need for separate OSB boards and house wrap layers. This consolidation reduces the number of installation steps and materials required, thereby shortening construction duration while maintaining wall completion quality
Solution Approach 2:
The spray foam material serves multiple functions simultaneously: it acts as an air barrier, provides structural bonding, seals gaps and joints, and contributes to thermal insulation. This multi-functionality replaces multiple separate materials (OSB, house wrap, fiberglass), thereby reducing construction steps and scheduling complexity while ensuring reliable wall completion
4Adaptability or versatility
If on-site insulation installation is performed, then flexibility is improved, but performance consistency and reliability decrease
Solution Approach 1:
The polyiso board is pre-manufactured with precise dimensions and high R-value properties in a controlled factory environment, ensuring consistent thermal performance. The spray foam material is applied on-site to seal gaps and adhere to the pre-installed board, combining the benefits of pre-manufacturing precision with on-site adaptability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The foam wall structure achieves higher thermal performance and structural stability, meeting future R-value standards while minimizing material and labor costs, and simplifying the installation process by eliminating the need for on-site insulation and additional materials.
Implementation Method 1
a foam layer received within at least a portion of one of the voids within the frame, wherein the foam layer adheres to at least a portion of the poly iso board
Data Source
AI summary
A foam wall structure includes a frame, at least one primary support member, a slab of polyiso board and a foam layer. The frame can include: a first member, a second member spaced apart from the first member; and two side members extending between the first and second members. The frame defining a front frame surface and an opposite rear frame surface. The at least one primary support member can be positioned between the two side members and extend between the first and second member. The primary support member defines a front support surface and an opposite rear support surface. The slab of polyiso board may be attached to the front frame surface. The foam layer can be received within at least a portion of the frame and overlies the front surface of the primary support member. A method of making a foam wall structure and a pre-fabricated wall is also disclosed.