Insulating wall assembly, and structure including the same

Abstract

An insulating wall assembly including a substantially rectangular framework having opposite interior and exterior sides, the framework including a plurality of vertical support studs mounted to a plurality of horizontal end studs so as to define at least one inner spacing within the framework, the vertical support studs and the horizontal end studs having each opposite front and rear sides corresponding to the interior and exterior sides of the framework. A foam of water-based polyurethane is injected into said at least one inner spacing so as to complete fill the same and provide the wall assembly with insulating capabilities. Outer components are mounted respectively onto the interior and exterior sides of the framework so as to close up the framework and provide the wall assembly with additional insulating capabilities.

1 . An insulating wall assembly comprising: 
 a substantially rectangular framework having opposite interior and exterior sides, the framework comprising a plurality of vertical support studs mounted to a plurality of horizontal end studs so as to define at least one inner spacing within the framework, the vertical support studs and the horizontal end studs having each opposite front and rear sides corresponding to the interior and exterior sides of the framework;    a foam of water-based polyurethane injected into said at least one inner spacing so as to complete fill the same and provide the wall assembly with insulating capabilities; and    outer components mounted respectively onto the interior and exterior sides of the framework so as to close up the framework and provide the wall assembly with additional insulating capabilities.    
   
   
       2 . An insulating wall assembly according to  claim 1 , wherein the outer components comprise a polyethylene cover mounted onto the front sides of the studs so as to entirely cover the interior side of the framework.  
   
   
       3 . An insulating wall assembly according to  claim 2 , wherein the outer components comprises a plurality of plates each being mounted respectively onto a front side of a corresponding vertical support stud, and a gypsum panel operatively mounted onto the front sides of the vertical support studs via the plates, an air space being defined between the polyethylene cover and the gypsum panel, said air space providing the wall assembly with additional insulating capabilities.  
   
   
       4 . An insulating wall assembly according to  claim 3 , wherein the outer components comprise a polyisocyanurate panel operatively mounted onto the rear sides of the studs so as to entirely cover the exterior side of the framework.  
   
   
       5 . An insulating wall assembly according to  claim 4 , wherein the plates are provided with AP foil bands.  
   
   
       6 . An insulating wall assembly according to  claim 5 , wherein each inner spacing comprises a traversal dividing stud connected between a pair of adjacent vertical support studs so as to divide said inner spacing into upper and lower inner spacings, said upper and lower inner spacings being completely filled with the foam of water-based polyurethane.  
   
   
       7 . An insulating wall assembly according to  claim 6 , wherein the foam of water-based polyurethane is a foam with open cells.  
   
   
       8 . An insulating wall assembly according to  claim 7 , wherein the foam of water-based polyurethane is a semi-rigid ½ pound density pour-in-place polyurethane foam.  
   
   
       9 . An insulating wall assembly according to  claim 8 , wherein the foam of water-based polyurethane is B500™ foam.  
   
   
       10 . An insulating wall assembly according to  claim 9 , wherein the vertical support studs and the horizontal end studs are 2″×6″ studs, the plates are 1″×2″ plates, adjacent vertical support studs are spaced apart from one another by about 16″, the thickness of the gypsum panel is about ½″, and the thickness of the polyisocyanurate panel is about ½″.  
   
   
       11 . An insulating wall assembly according to  claim 10 , wherein the overall R value of the insulating wall assembly is about R30.  
   
   
       12 . A structure at least one insulating wall assembly, each insulating wall assembly comprising: 
 a substantially rectangular framework having opposite interior and exterior sides, the framework comprising a plurality of vertical support studs mounted to a plurality of horizontal end studs so as to define at least one inner spacing within the framework, the vertical support studs and the horizontal end studs having each opposite front and rear sides corresponding to the interior and exterior sides of the framework;    a foam of water-based polyurethane injected into said at least one inner spacing so as to complete fill the same and provide the wall assembly with insulating capabilities; and    outer components mounted respectively onto the interior and exterior sides of the framework so as to close up the framework and provide the wall assembly with additional insulating capabilities.    
   
   
       13 . A structure according to  claim 12 , wherein the outer components comprise a polyethylene cover mounted onto the front sides of the studs so as to entirely cover the interior side of the framework.  
   
   
       14 . A structure according to  claim 13 , wherein the outer components comprises a plurality of plates each being mounted respectively onto a front side of a corresponding vertical support stud, and a gypsum panel operatively mounted onto the front sides of the vertical support studs via the plates, an air space being defined between the polyethylene cover and the gypsum panel, said air space providing the wall assembly with additional insulating capabilities.  
   
   
       15 . A structure according to  claim 14 , wherein the outer components comprise a polyisocyanurate panel operatively mounted onto the rear sides of the studs so as to entirely cover the exterior side of the framework.  
   
   
       16 . A structure according to  claim 15 , wherein the plates are provided with AP foil bands.  
   
   
       17 . A structure according to  claim 16 , wherein each inner spacing comprises a traversal dividing stud connected between a pair of adjacent vertical support studs so as to divide said inner spacing into upper and lower inner spacings, said upper and lower inner spacings being completely filled with the foam of water-based polyurethane.  
   
   
       18 . A structure according to  claim 17 , wherein the foam of water-based polyurethane is a foam with open cells.  
   
   
       19 . An insulating wall assembly according to  claim 18 , wherein the foam of water-based polyurethane is a semi-rigid ½ pound density pour-in-place polyurethane foam, commercialized under B500™.  
   
   
       20 . A kit for assembling an insulating wall assembly, comprising: 
 a substantially rectangular framework having opposite interior and exterior sides, the framework comprising a plurality of vertical support studs mountable to a plurality of horizontal end studs so as to define at least one inner spacing within the framework, the vertical support studs and the horizontal end studs having each opposite front and rear sides corresponding to the interior and exterior sides of the framework;    a foam of water-based polyurethane injectable into said at least one inner spacing so as to complete fill the same and provide the wall assembly with insulating capabilities; and    outer components mountable respectively onto the interior and exterior sides of the framework so as to close up the framework and provide the wall assembly with additional insulating capabilities.