System, method and apparatus for compressed insulation

Abstract

An insulation product may include a container, a first insulation material forming a first layer inside the container, and a second insulation material forming a second layer inside the container, and the first layer is compressed by the second layer. A structure in a building may include studs, first and second claddings mounted to opposite sides of the studs, and structure spaces defined between the studs and the opposing claddings. A first insulation material may include first layers on and substantially covering a first one of the claddings inside the structure spaces. In addition, a second insulation material may have second layers inside the structure spaces. The first layers are compressed and substantially covered by the second layers, and the second layers substantially cover a second one of the claddings inside the structure spaces.

What is claimed is: 
     
         1 . An insulation product, comprising:
 a container;   a first insulation material forming a first layer inside the container; and   a second insulation material forming a second layer inside the container, and the first layer is compressed by the second layer.   
     
     
         2 . The insulation product of  claim 1 , wherein the first insulation material comprises at least one of compressible insulation, an organic material, a compressible mineral material, a synthetic material, cellulose, fiberglass, polyester fibers, polyethylene fibers, glass wool, stone wool, sheep wool, wood fibers, cotton, hemp, flax, cork, straw, feathers and chopped recycled cloth. 
     
     
         3 . The insulation product of  claim 1 , wherein the second insulation material comprises at least one of a foam, a spray foam and a slow rise spray foam. 
     
     
         4 . The insulation product of  claim 1 , wherein the second insulation material comprises at least one of isocyanate, methylene diphenyl diisocyanate (MDI), polyol resin and polyether polyols. 
     
     
         5 . The insulation product of  claim 1 , wherein the second insulation material comprises at least one commercially available expanding foam. 
     
     
         6 . The insulation product of  claim 1 , wherein the second insulation material comprises an airtight layer in the insulation product. 
     
     
         7 . The insulation product of  claim 9 , wherein the airtight layer comprises an air permeance of less than about 0.004 L/(s·m 2 ) @ 75 Pa for a one inch thickness. 
     
     
         8 . The insulation product of  claim 1 , wherein the second insulation material has a water vapor permeance of not greater than about 2 perms/inch. 
     
     
         9 . The insulation product of  claim 1 , wherein the first layer comprises at least one liner, facing and barrier between the first layer and the second layer. 
     
     
         10 . The insulation product of  claim 1 , wherein the first insulation material comprises:
 an uncompressed density of at least about at least about 0.35 lb/ft 3 , and not greater than about 2.8 lb/ft 3 ; and   a compressed density inside the container of at least about 0.62 lb/ft 3 , and not greater than about 3 lb/ft 3 .   
     
     
         11 . The insulation product of  claim 1 , wherein the second insulation material has a density of at least about 0.25 lb/ft 3 , and not greater than about 3 lb/ft 3 . 
     
     
         12 . The insulation product of  claim 1 , wherein the first insulation material is compressed by at least about 10%, and not greater than about 80%. 
     
     
         13 . The insulation product of  claim 1 , wherein a thickness ratio (TR) is defined as a thickness of the compressed first layer (TF) to a thickness of the second layer (TS), and the thickness ratio (TR=TF/TS) is at least about 0.1, and not greater than about 0.9. 
     
     
         14 . The insulation product of  claim 1 , wherein the first layer substantially covers an entire interior surface of the container, the second layer substantially covers an entire opposite interior surface of the container, and the second layer substantially covers and compresses an entire surface of the first layer. 
     
     
         15 . The insulation product of  claim 1 , wherein the first insulation material comprises:
 an uncompressed thermal resistance (R-value) of at least about R10, and not greater than about R25; and   a compressed R-value of at least about R12, and not greater than about R34.   
     
     
         16 . The insulation product of  claim 1 , wherein the container is portable. 
     
     
         17 . The insulation product of  claim 1 , wherein the container can be cut to length, the container can be cut to width, but the container cannot be cut to depth. 
     
     
         18 . The insulation product of  claim 1 , wherein the insulation product comprises an overall thermal resistance (R-value, aged) of at least about R12, and not greater than about R23. 
     
     
         19 . A structure in a building, comprising:
 studs, first and second claddings mounted to opposite sides of the studs, and structure spaces defined between the studs and the opposing claddings;   a first insulation material comprising first layers on and substantially covering a first one of the claddings inside the structure spaces; and   a second insulation material comprising second layers inside the structure spaces, the first layers are compressed and substantially covered by the second layers, and the second layers substantially cover a second one of the claddings inside the structure spaces.   
     
     
         20 . A structure in a building, comprising:
 studs, first and second claddings mounted to opposite sides of the studs, and structure spaces defined between the studs and the claddings;   two different types of insulation in the structure spaces, with a second type of the insulation compressing a first type of the insulation; and   at least about 80% of the structure meets a specification comprising:
 a thermal conductivity (λ) in a range of about 0.14 Btu·in/(ft 2 ·hr·F) to about 0.28 Btu·in; 
 a thermal resistance (R-value) in a range of about R13 to about R22; 
 an acoustic property comprising noise reduction in a range of about 33 dB to about 40 dB; and 
 an average density in a range of about 0.063 lb/ft 3  to about 1.87 lb/ft 3 .