Insulated panels and methods of enhancing thermal insulation of structures using same

Abstract

The present disclosure provides insulated panels comprising a core layer including an insulating material, an interior-side sheathing layer, and an exterior-side sheathing layer. The insulated panels of the present disclosure can be used to conveniently retrofit existing structures to dramatically improve thermal insulation performance without substantially increasing a risk of moisture retention or mold formation within the structure's walls.

1 - 20 . (canceled) 
     
     
         21 . An insulating core-shell construction panel comprising:
 a core comprising thermal insulation component and an internal frame component dispersed throughout the thermal insulation component; and   a shell surrounding the core and comprising:
 an external frame surrounding a perimeter of the core and having an external face and an internal face opposite the external face, 
 an external sheathing layer disposed on the external face of the external frame, and 
 an internal sheathing layer disposed on the internal face of the external frame. 
   
     
     
         22 . The insulating core-shell construction panel of  claim 21 , wherein the thermal insulation component comprises, consists essentially of, or consists of any one or more of: extruded polystyrene, spray foam, and stone wool batt. 
     
     
         23 . The insulating core-shell construction panel of  claim 21 , wherein the internal frame component represents not more than about 20% of a cross-sectional area of the core. 
     
     
         24 . The insulating core-shell construction panel of  claim 21 , wherein the internal frame component includes at least one horizonal internal frame member and optionally at least one vertical internal frame member. 
     
     
         25 . The insulating core-shell construction panel of  claim 21 , wherein the external frame comprises a bottom frame member, at least one vertical frame member, and a top frame member. 
     
     
         26 . The insulating core-shell construction panel of  claim 21 , wherein the external sheathing layer comprises, consists essentially of, or consists of any one or more of: plywood, pressboard, oriented strand board, gypsum, glass mat, cement board, and long-fibered water-and weather-resistant engineered panels. 
     
     
         27 . The insulating core-shell construction panel of  claim 21 , wherein the internal sheathing layer comprises, consists essentially of, or consists of foam sheathing. 
     
     
         28 . The insulating core-shell construction panel of  claim 21 , wherein the shell further comprises a water-resistant barrier layer disposed on an exterior face of the exterior sheathing layer. 
     
     
         29 . The insulating core-shell construction panel of  claim 21 , wherein the internal sheathing layer comprises a drainable sheathing portion configured to enable moisture to exit the insulating core-shell construction panel from the core. 
     
     
         30 . A method of enhancing thermal insulation performance of a wall, the method comprising:
 removing an exterior siding layer and associated furr strips, if present, to expose an existing exterior sheathing layer of the wall;   attaching an insulating core-shell construction panel of  claim 21  to the existing exterior sheathing of the wall; and   attaching an exterior siding layer to an exterior surface of the insulated panel or the insulating core-shell construction panel.   
     
     
         31 . The method of  claim 30  further comprising anchoring a panel support to the wall or to a foundation supporting the wall. 
     
     
         32 . The method of  claim 31 , wherein the step of attaching comprises resting the insulating core-shell construction panel on the panel support. 
     
     
         33 . The method of  claim 31 , wherein a thermal insulation rating of the wall in increased by an added insulation value of at least R-10, for example at least R-10, at least R-11, at least R-12, at least R-13, at least R-14, at least R-15, at least R-16, at least R-17, at least R-18, at least R-19, at least R-20, at least R-21, at least R-22, at least R-23, at least R-24, at least R-25, at least R-26, at least R-27, at least R-28, at least R-29, at least R-30, or greater than an R-30 added insulation value.