Wall insulation system and a method of installing the same

Abstract

The embodiments of the invention includes a retrofitting system for the insulation of existing interior walls such as basements; a retrofitting system for the insulation of exterior walls of a structure such as a home needing further insulation without a convenient or economical method to do so within the interior walls, the inclusion of insulation within the concrete walls of a structure constructed by the tilt-up construction method and a use of elements of the insulated wall system to effectively insulate and provide continuous studding in a conventional “cast-in-place” concrete wall assembly, subsequent to placing concrete. The insulated wall systems of these embodiments provide an economical and efficient method of providing the installation of insulation panels to each of the walls described. The insulation panels are generally of a foam structure supported by connecting and/or corner studs. The connecting studs and corner studs are of a unique design that are easily fastened to an existing wall or made part of a Tilt-up Wall system or a “cast-in-place” system. In addition to supporting the Insulation panels, the studs are structured to provide a moisture gap between the insulation and the exiting wall to which they are mounted. The connecting stud and corner studs also provide for wire chase areas for power distribution with a wall system.

1 . A stud comprising:
 a. a top portion;   b. a supporting leg;   c. wall mounting portion;   d. one or more wire chase portions;   e. one or more insulation panel support areas; and   f. one or more moisture protection areas   g. wherein said studs provide support for insulation panels, provide one or more wire chase areas and protect said insulation panels from moisture.   
     
     
         2 . The stud of  claim 1  comprising:
 a. a connecting stud that provides support of up to two insulation panels and further comprises: 
 b. two insulation panel support areas for supporting up to two insulation panels; 
 c. two said wire chase areas; 
 d. two said moisture protection areas. 
 
     
     
         3 . The stud of  claim 1  comprising:
 a. a corner stud that supports one insulation panel and provides a corner structure for a wall system and 
 b. further comprises: one insulation panel support area supporting a single insulation panel; 
 c. one said wire chase area; 
 d. one said moisture protection area. 
 
     
     
         4 . The stud of  claim 2  wherein said connecting stud comprises:
 a. a wall mounting portion 3.25 inches in width and a depth of approximately 0.093 inches; 
 b. a connecting portion 3.00 inches in height and a width of approximately 0.093 inches centered upon; 
 c. a top portion 2.00 inches in width centered upon said wall mounting portion; 
 a pair of wire chase portions mounted on either side of said connecting portion upon said wall portion, each wire portion having a width of 0.86 inches and a height of approximately 0.73 inches; and 
 an overall length of up to 96 inches or a length governed by height of said wall. 
 
     
     
         5 . The stud of  claim 2  wherein said corner stud comprises:
 a bottom portion 1.75 inches in width and a thickness of approximately 0.93 inches; 
 a. a connecting portion 3.00 inches in height and approximately 0.90 inches in width; and 
 b. a top portion 1.25 inches wide and 0.093 inches thick and a length of up to 96 inches. 
 
     
     
         6 . The system of  claim 1  wherein a material of said studs is selected from the group consisting of PVC, aluminum, Polypropylene, reinforced fiberglass, or Polycarbonate. 
     
     
         7 . The system of  claim 1  wherein said studs are made of durable PVC. 
     
     
         8 . An insulated wall system comprising:
 a. one or more connecting studs;   b. one or more corner studs;   c. one or more insulation panels;   d. one or more corner insulation inserts;   e. wherein said studs are mounted to a wall;   f. further wherein said insulation panels are coupled to a pair of one or more studs and said corner insulation inserts are coupled to one or more studs.   
     
     
         9 . The system of  claim 8  wherein said connecting studs are glued to said wall. 
     
     
         10 . The system of  claim 8  wherein said connecting studs are mechanically fastened to said wall. 
     
     
         11 . The system of  claim 8  wherein said connecting studs are incorporated within a linear portion of an insulated wall system. 
     
     
         12 . The system of  claim 8  wherein a connecting stud and/or one or more corner studs are used to form a corner within said wall system. 
     
     
         13 . The system of  claim 8  wherein said system is mounted on to an interior wall. 
     
     
         14 . The system of  claim 8  wherein said system is mounted on to an exterior wall. 
     
     
         15 . The system of  claim 8  wherein said wall is made of concrete. 
     
     
         16 . The system of  claim 8  wherein said wall is a concrete masonry unit constructed wall. 
     
     
         17 . The system of  claim 8  wherein said insulation panels are made of materials selected from the group consisting of Expanded Polystyrene, Extruded Polystyrene, or Polyisocyanurate, Mineral board, rock-wool or Fiberglass. 
     
     
         18 . The system of  claim 8  wherein said insulation panels are up to 24″ in width, 2″ in depth and a length of up to 96″ or a length governed by a height of said wall. 
     
     
         19 . The system of  claim 8  comprises a series of sections further comprising sections of continuous studding and insulation panels. 
     
     
         20 . The system of  claim 8  wherein said system as mounted to said wall includes an air space between said one or more insulation panels and said wall. 
     
     
         21 . The system of  claim 8  comprising one or more wire chases within each of said one or more studs. 
     
     
         22 . The system of  claim 8  comprising one or more inner corner subsystems further comprising:
 a. a corner stud; 
 b. a connecting stud; and 
 c. a first corner insulated insert. 
 
     
     
         23 . The system of  claim 22  wherein said corner insulated insert has a depth of 2 inches and width of 3 inches and an overall length of up to 96 inches or a length governed by a height of said wall. 
     
     
         24 . The system of  claim 8  comprising one or more outer corner subsystems further comprising:
 a. a corner stud; and 
 b. a second corner insulated insert. 
 
     
     
         25 . The system of  claim 24  wherein said corner insulated insert has a depth of 2 inches and width of 5 inches and an overall length of up to 96 inches or a length governed by a height of said wall. 
     
     
         26 . A kit of parts for an insulated wall system of  claim 1  comprising:
 a. one or more connecting studs; 
 b. one or more corner studs; 
 c. one or more corner insulation inserts; 
 d. wherein said parts are combined with user supplied one or more insulation panels for installation on or as part of a wall. 
 
     
     
         27 . A kit of parts for an insulated wall system of  claim 1  comprising:
 a. one or more connecting studs; 
 b. one or more corner studs; and 
 c. one or more corner insulation panels; 
 d. one or more insulation panels; 
 e. wherein said parts are combined for installation on a or as part of a wall. 
 
     
     
         28 . A kit of parts for an insulated wall system of  claim 1  comprising:
 a. one or more connecting studs; 
 b. one or more corner studs; and 
 c. wherein said parts are combined with user supplied one or more insulation panels and user cut and shaped insulation panels to form one or more corner insulation inserts for installation on to or fabricated as part of a wall. 
 
     
     
         29 . A method of installing an insulated wall system comprising the acts of:
 a. installing an inside corner portion of said system an inside corner of an existing wall if said wall has one or more inside corners;   b. installing one more connecting portions having no openings;   c. installing one or more door portions, if said wall comprises one or more door openings;   d. installing one or more window portions, if said wall has one or more window openings;   e. coupling one or more additional connecting portions to said openings;   f. installing one or more outside corner portions, if said wall has one or more outside corners; and   g. installing a first end of wall portion; and/or installing a second end of wall portion.   
     
     
         30 . The method of  claim 29  wherein installing an inside corner portion further comprises the acts of:
 a. insert a first corner insulation insert into a first side of a connecting stud; 
 b. liberally apply a bead of construction adhesive to a base side of said connecting stud; 
 c. position said connecting stud with said first corner insulation insert so that the first corner insulation insert is pushing snug against said first wall; 
 d. then press said connecting stud against said first wall allowing said adhesive to form a tack bond; 
 e. liberally apply a bead of adhesive to a base surface of a corner stud; 
 f. apply a bead of adhesive to a surface of a top surface of said connecting stud allowing said adhesive to form a tack bond between said corner stud and said connecting stud; and 
 g. press said Corner Stud simultaneously against a second wall and against said Top Surface of said Connecting Stud. 
 
     
     
         31 . Said method of  claim 28  wherein 2 or 3 Masonry Screws through a mounting flange said corner stud may be used to further secure said corner stud to said second wall and/or said screws through a mounting flange of said connecting stud to further secure said connecting stud to said first wall or may be used in place of said adhesive. 
     
     
         32 . The method of  claim 29  wherein installing an outside corner portion further comprises the acts of:
 a. liberally applying a bead of adhesive to a back side of a corner stud; 
 b. liberally applying a bead of adhesive to a back side of a corner stud; 
 
     
     
         33 . insure that said corner stud is flush with a wall corner and press it firmly against said wall allowing the adhesive to form a tack bond with a surface of said wall. The method of  claim 29  wherein installing one more connecting portions having no openings comprising the acts of:
 a. liberally apply a bead of adhesive to a back side of a first connecting stud; 
 b. Slide said a first side of said first connecting stud over a first Insulation panel; 
 c. Apply said first connecting stud to a wall; and 
 d. Slide a second Insulation panel into a second side of said first connecting stud; and repeat above steps as necessary. 
 
     
     
         34 . The method of  claim 29  wherein installing a connecting portion having a window opening further comprises the acts of:
 a. installing an Insulation panel around a first side of said wind opening; 
 b. installing a first above window connecting stud; 
 c. installing a first below window connecting stud; 
 d. installing an above window insulation panel and a below window insulated panel; 
 e. installing an insulation panel around a second side of said window opening; and; 
 f. Installing trim around window opening edges. 
 
     
     
         35 . The method of  claim 29  wherein installing a connecting portion having a door opening further comprises the acts of:
 a. installing an insulation panel around a first side of said door opening; 
 b. installing a first above window connecting stud; 
 c. installing an above window Insulation panel; 
 d. installing an Insulation panel around a second side of said door opening; and 
 e. installing an Insulation panel around a second side of said door opening; and; 
 installing trim around door opening edges. 
 
     
     
         36 . The method  claim 20  wherein the method of installing a first end of wall portion comprises the steps of:
 a. apply a liberal amount of adhesive to a connecting stud mounting surface and place it against said wall flush with an existing insulation panel and check for plumb; 
 b. press said connecting stud firmly against said wall allowing said adhesive to form a tack bond with said wall surface; 
 c. measure a distance from a support leg of said connecting stud to an end of said wall; 
 d. cut an end insulation panel to said measurements while allowing an additional ⅛ inch to compensate for a corner stud's material thickness; 
 e. slide said end insulation panel into said connector stud; 
 f. apply a liberal amount of adhesive to a back mounting surface of said corner stud and slide said corner stud onto an edge of said end insulation panel; and 
 g. press said corner stud firmly against said wall allowing said adhesive to form a tack bond with a surface of said wall. 
 
     
     
         37 . The method  claim 20  wherein the method of installing a second end of wall portion comprises the steps of:
 a. apply a liberal amount of adhesive to a back mounting surface of a corner stud and slide said corner stud onto an edge of an insulation panel at said end of the wall; and 
 b. press said corner stud firmly against said wall allowing said adhesive to form a tack bond with surface of said wall. 
 
     
     
         38 . A method of installing an insulated wall system within a tilt-up wall system comprising the acts of:
 a. installing a first corner stud next to a first interior edge of a tilt-up wall panel form;   b. inserting a first side of a first insulation panel into said Corner Stud;   c. placing a first connecting stud is placed on a slab portion of said tilt-up wall panel form and inserted on to a second side of said first insulation panel;   d. continuing step c with one or more additional connecting studs and one or more additional insulation panels with at least one of the additional insulation panels may be needing to be cut into a shorter width in order to fit within said tilt-wall panel form including a second corner stud;   e. installing one or more rebar chair on top of each connecting stud;   f. installing rebar on to said rebar chairs; and   g. pouring concrete into said tilt-up wall panel form.   
     
     
         39 . The method of  claim 38  further comprising the act of:
 a. installing an additional insulation panel above each said insulation panel and in between said studs, wherein said additional insulation panels improves the R rating of said tilt-up system. 
 
     
     
         40 . The method of  claim 38  further comprising the act of:
 a. installing a one piece insulation panel having “legs” on it with the thickness that fits within corner stud or connecting stud and having a center area greater than between said studs, wherein said one piece insulation panels improve the R rating of said tilt-up system; 
 b. mounting rebar chairs on to each stud; and 
 c. creates a structural element to the wall assembly 
 
     
     
         41 . A method of installing an insulated wall system within a cast-in-place application: comprising the acts of:
 a. installing a series of wall forms into which a “cast-in-place” system is installed;   b. installing a plurality of wall ties;   c. installing a plurality of connector studs with a base side protruding into an open wall cavity;   d. installing one or more corner studs with a base side protruding into said open wall cavity;   e. cutting insulation panels to spacing between connector studs or between connector studs and a corner stud;   f. installing one or more connector studs and one or more insulation panels between one or more wall ties.   
     
     
         42 . The method of  claim 41  wherein said connector studs are spaced 12 inches on center up to 24 inches on center. 
     
     
         43 . The method of  claim 42  wherein said insulation panels are cut to size in order to create uniform spacing between connector studs. 
     
     
         44 . A method of installing an insulated wall system onto an existing exterior of a building comprising the acts of:
 a. applying the acts of  claims 29  through  35  to said exterior of a building.