CONTAINED FOAM ENVELOPE FOR INSULATING AND SEALING LARGE VOLUMES

Abstract

A system for sealing large volumes or gaps includes a flexible envelope that can assume the shape of the volume when filled with a foaming composition that expands the envelope to the boundaries of the volume. The foaming composition may be integral with the envelope or delivered in bulk by an external device. The foaming composition may be one or multiple parts, typically two parts such as a poly isocyanate and a polyols, in which case it is necessary to keep the two parts separate until foaming is desired. Separation may be accomplished by providing multiple compartments that deliver components via a mixing device into the interior. The envelope may include ribs for structural strength and shaping, and leak pores around its perimeter to enhance bonding and sealing. It may also include perforations for bulk, modular seals or for separation of portions of the envelope to seal irregular shapes.

Claims

1-8. (canceled)

9. A method for sealing or insulating a large volume, the method comprising: placing within the large volume against at least one substrate; a self contained system for sealing or insulating a large volume, the system comprising: an envelope having walls defining an interior and at least one separate compartment in fluid communication with the interior, the compartment housing at least one component of a foaming composition; and an activation trigger configured, upon activation, to mix the components of the foaming composition and deliver them to the interior of the envelope to initiate a foaming reaction within the envelope and activating the trigger to initiate the foaming reaction.

10. The method of claim 9 wherein a retrofit envelope is inserted into an enclosed volume space through a smaller orifice in one of the substrate surfaces.

11. The method of claim 10 wherein the envelope is first rolled up for insertion through a smaller orifice and as the foaming composition expands, the envelope unrolls to fill the volume.

12. The method of claim 9 wherein the step of activating the trigger comprises depressing a plunger.

13. The method of claim 9 wherein the step of activating the trigger comprises pinch rolling a flexible sided compartment of the envelope.

14-24. (canceled)

25. A method for sealing or insulating a large volume comprising: placing an envelope within the large volume against at least one substrate; the envelope having walls defining an interior, and an exterior fitment in one wall, the fitment being in fluid communication with the interior of the envelope and being dimensioned to sealingly engage the outlet of a delivery device for connecting to a source of components of a foaming composition and delivering the foaming composition to the interior of the envelope through the fitment; and a matrix disposed in the envelope interior adjacent to the fitment to mix components of a foaming composition, delivering a quantity of components of the foaming composition to the interior of the envelope through a delivery device connected to the source of components of the foaming composition and to the exterior fitment, whereby the components are mixed within the matrix to initiate a foaming reaction within the envelope.

26. The method of claim 25 wherein the foaming composition is a two part foaming composition.

27. The method of claim 25 wherein the matrix within the interior of the envelope further comprises an impervious backing that forces the foaming composition delivered to the fitment to disperse into the interior in a direction non-parallel to the delivery through the fitment.

28-32. (canceled)

33. A method for sealing or insulating a large volume using an envelope system, the envelope system comprising a plurality of envelopes each having walls defining an interior and an exterior fitment in fluid communication with the interior; the fitment being adapted to receive a delivery device for delivering components of a foaming composition to the interior of the envelope; each envelope being joined to at least one other envelope along a common side, the common side having a series of perforations for separating one envelope from the other the method comprising: separating a portion of the plurality of envelopes as needed to create a a modified envelope system to fit an irregular volume; placing the modified envelope system within the large volume against at least one substrate; delivering to the interior of the envelope through the delivery device connected to the source of components of a foaming composition and to the exterior fitment a quantity of components of the foaming composition mixed to initiate a foaming reaction within the envelope.

34. The method of claim 33 wherein the foaming composition is a two-part composition and the two parts are mixed prior to delivery to the interior of the envelope.

35. The method of claim 33 further comprising a matrix disposed in the envelope interior adjacent the fitment, and wherein the foaming composition is a two-part composition and the two parts are mixed in the matrix within the interior of the envelope.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0032] FIG. 1 is a side view of a typical exterior construction, showing the band joist areas of a ground floor and second floor.

[0033] FIG. 2 is a side view of typical construction of an overhang or extension of second story living space over exterior or unconditioned garage space.

[0034] FIG. 3A is a front view of an envelope seal according to the invention

[0035] FIG. 3B is an enlarged, partly cutaway view of a portion of the envelope seal of FIG. 3A, and showing one embodiment of an activator for use with the invention.

[0036] FIGS. 4A and 4B are side views of an exterior wall as in FIG. 1, showing floor and ceiling installations of large volume envelope sealing devices. FIG. 4A shows the wall before installation and FIG. 4B shows the wall after installation and activation of the envelope seal.

[0037] FIGS. 5A and 5B show alternative methods of installation to a band joist large gap area.

[0038] FIG. 6A is a front view of an alternate embodiment of the envelope seal; FIG. 6B is cross sectional view of this embodiment taken along line B-B of FIG. 6A.

[0039] FIGS. 7A and 7B show an alternate embodiment of an activation device; before and during activation.

[0040] FIG. 8 shows an alternate embodiment of an envelope seal, including a mixing matrix inside the envelope.

[0041] FIGS. 9A and 9B show variations of the envelope seal that include perforations for separating portions of the bag to improve the fit around specific spaces.

DETAILED DESCRIPTION OF THE INVENTION

[0042] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are described herein. All references cited herein, including published or corresponding U.S. or foreign patent applications, issued U.S. or foreign patents, and any other references, are each incorporated by reference in their entireties, including all data, tables, figures, and text presented in the cited references.

[0043] The term R-value is the commercial unit used to measure the effectiveness of thermal insulation and is the reciprocal of its thermal conductance which, for slab materials having substantially parallel faces, is defined as the rate of flow of thermal energy (BTU/hr or Watt) per unit area (square foot=ft.sup.2 or square meter=m.sup.2) per degree of temperature difference (Fahrenheit or Kelvin) across the thickness of the slab material (inches or meters). Inconsistencies in the literature sometimes confuse the intrinsic thermal properties resistivity, r, (and conductivity, k), with the total material properties resistance, R, (and conductance, C), the difference being that the intrinsic properties are defined as being per unit thickness, whereas resistance and conductance (often modified by total) are dependent on the thickness of the material, which may or may not be 1 unit. This confusion, compounded by multiple measurement systems, produces an array of complex and confusing units the most common of which are:

TABLE-US-00001 English (inch-pound) Metric/SI units Intrinsic resistivity, r (conductivity, k, is reciprocal) [00001]$\frac{\mathrm{hr}*{\mathrm{ft}}^2*.Math..Math.F.}{\mathrm{BTU}*\mathrm{in}}$ [00002]$\frac{K*m}{W}$ Total material resistance, R (conductance, C, is reciprocal) [00003]$\frac{\mathrm{hr}*{\mathrm{ft}}^2*.Math..Math.F.}{\mathrm{BTU}}$ [00004]$\frac{K*m^2}{W}$

[0044] For ease of comparisons of materials of differing thicknesses, the building industry sometimes reports thermal resistance (or conductance) per unit thickness (e.g. per inch) effectively converting it to thermal resistivity (conductivity), but retains the traditional symbol, R or R-value.

[0045] FIG. 1 illustrates a typical construction of an exterior wall of a residential unit, although the invention is by no means limited to residential construction. It shows two examples of typical large gap joist areas 10, 11 that can benefit from the invention. A foundation wall 12 is provided on a footing (not shown). A sill plate 14 is anchored to the top of the foundation wall 12, typically using an embedded bolt and nut arrangement 16. On top of the sill plate 14 rests all the flooring joists 18 (one shown) as well as the outer rim or band joist 20, shown in cross section. The joists 18 support the subfloor 22, on which rests bottom plate 24 to support studs 26 for an exterior wall. The exterior wall may include sheathing 28 and/or other coverings on the exterior side, and a wall panel such as drywall 30 on the interior of the unit. A large gap 10 exists the area between joists 18 and bounded by the upper surface 14A of sill plate 14, the interior surface 20A of band joist 20 and the under surface 22A of the subfloor 22. If the basement is finished, there may be ceiling material (not shown) fastened to the underside of joists 18 to provide an additional boundary of the large gap 10.

[0046] In similar fashion, a two-story unit has a similar large gap joist space 11, shown in the upper part of FIG. 1. The wall studs 26 support a top plate 34, typically one or more 24s, on which are supported the upper story flooring joists 38 (one shown) as well as the outer rim or band joist 40, shown in cross section. The joists 38 support the subfloor 42, on which rests bottom plate 44 to support studs 46 for an upper story exterior wall. As with the lower story, the exterior wall typically includes sheathing 28 and/or other covering materials on the exterior side and a wall panel such as drywall 50 on the interior of the unit. The large gap 11 is the area between joists 38 bounded by the under surface 42A of the subfloor 42, the interior surface 40A of the band joist 40, and by the upper surface of top plate 34 and/or ceiling 52. In some cases, a scrap block 54 is fastened to the upper surface of the top plate to provide an undersurface to which the ceiling 52 can be fastened. Thus the top surface of the top plate, the top surface of the block 54 or the top surface of the ceiling 52 all may potentially provide a lower boundary of the large air gap 11.

[0047] FIG. 2 illustrates additional types of large air gaps 60, 61 that do not abut and are not bounded by a band joist. FIG. 2 depicts a stud wall 66 that divides conditioned space 68 (on the left side of the wall 66 shown in FIG. 2) and unconditioned space 70 (on the right side of the wall 66). The unconditioned space may be, for example, a garage, a porch, a crawl-space or simply the exterior over which an overhang extends. Wall 66 terminates at its upper end with a top plate 72, upon which floor joists 74 extend to support the subflooring 76 of a second story. In a two story building, or even in the attic space of a one story building, subflooring 76 may support additional walls 78, built up from a sole plate 80, that divide conditioned space 82 from unconditioned space 84. The large gap areas 60, 61 are thus the interjoist area between joists 74 bounded on the top by subfloor 76 and on the bottom by top plate 72 and/or ceiling 52. There is no band joist bounding the gap 60, 61 in a third dimension. For a discussion of sealing air leaks, gap 60 may be viewed as the area that amounts to an extension of the wall 66 upward into the interjoist space; and gap 61 may be viewed as the area that amounts to an extension of the wall 78 downward into the interjoist space.

[0048] It is customary in cooler climates to install insulation in the interjoist spaces between conditioned area 82 and unconditioned area 70. However, typical insulation does little to prevent air leaks and drafts from flowing through the interjoist spaces right along the joists. Sealing as used herein refers to the prevention or hindering of the movement of air such as drafts (i.e. convection) that can move through cavities, gaps, and poorly sealed seams whereas insulating refers to the prevention or hindering of all forms of heat transfer, including convection, conduction and radiation. Thus, sealing is a specialized case of insulating. Sealing is also important for noise reduction. The present invention addresses the shortcomings of using only insulation in interjoist spaces.

[0049] Some typical large volume areas are discussed above and illustrated in FIGS. 1 and 2. However, other large volumes may exist in home or building construction and also may benefit from the invention. For example, masonry chimneys often extend through a second floor and/or rafters. There frequently is a large gap between the masonry and the framing lumber. Additionally, chases are sometimes designed and built into homes for the passage of wiring, plumbing and exhaust flues. It is common to install water heaters and furnaces in the basement and to vent their exhaust gases through the roof, requiring a chase throughout all floors. The opening of the chase into the attic (or wherever it changes from conditioned to unconditioned space) represents another large gap that could and should be sealed against drafts and air leaks.

[0050] While the above examples of large volumes, cavities or gaps are given, it should be appreciated that these are not the only embodiments of large gaps. Large gaps do not have any particular minimum dimensions or shape, and other large gaps may also be envisioned and suitable for sealing using the envelope seals described herein. Generally, however, gaps or cavities are considered large if they encompass a volume of at last 6 cubic inches, more likely at least 12, 24, 48 or 64 cubic inches, and they may be as large as several cubic feet. Although discussed in terms of volume and cavities, the depth dimension is more applicable when additional R-value or insulation is desired. For sealing alone, a very thin envelope having just two dimensions is suitable, and one might describe it in terms of the area of the gap, but as a practical matter some insulation effect is often desired as well and the envelope will have some thickness and volume to provide this. Sealing or insulating or both are all aspects of the invention.

[0051] A large volume or gap is always bounded by a substrate on at least one side and usually, at least 2, 3 or more substrate/sides. Interjoist gaps are bounded by the two joists as well as one or more of a floor, a ceiling, a top plate, a sill plate and optionally by a band joist. Masonry gaps mentioned above are bounded by the masonry and a rafter or other framing structure as substrates. Similarly, a chase is bounded by substrate walls that form the chase. These substrates provide surfaces to which envelope seals may be lodged against or attached.

[0052] In some embodiments, the large volumes or gaps may not be in residential or building construction at all, but may occur in automotive, aircraft, marine or other vehicles, or in appliances such as dishwashers, dryers, ovens, refrigerators and the like. Any cavity, void or gap that needs to be sealed or insulated or both is potentially a large volume gap in accordance with the invention.

[0053] In order to fill and seal the large gaps described above, the invention provides in a first integral or self-contained embodiment an envelope or bag that already contains a quantity of a foaming composition that can be triggered externally to initiate a foaming reaction internally within the envelope to expand it to fill and seal the large volume. The foaming composition may be thought of as a unit dose for the intended envelope or container. Foaming compositions are described below. They are typically, though not necessarily, made in two parts which, like epoxies, are kept separated until ready for use. Activation triggers are used to combine the two parts to initiate the foaming reaction. In a different, bulk embodiment the bag or envelope does not initially contain the foaming composition or an activation device, but instead contains a fitment into which a foaming composition can be injected. The foaming compositions, if two-part, may be mixed in the delivery device just prior to injection into the envelope, or they may be delivered unmixed and mixed within a matrix inside the envelope. Several embodiments of the envelope or bag, including activation triggers and fitments, are described below in connection with multiple embodiments and with reference to the drawing figures.

Envelopes and Activators

[0054] The term envelope is synonymous with bag, sac, bladder and similar terms that convey a sealed or sealable container with flexible walls. The envelope may be relatively flat, or it may have side walls or pleats to give it some depth when expanded. The envelope walls may be elastic and stretch to expand and conform to the volume space it is designed to fill, yet it should be strong enough to absorb the expanding foam in its interior without bursting. In some embodiments, the envelope walls may be sized and shaped to produce a gap filling envelope of specific dimensions and/or shape. At the same time, the foaming composition is matched in type and quantity to the specific envelope and is self-contained within or adjacent the envelope for an integral package. FIGS. 3 and 4 illustrate such an integral package. In other embodiments, the foaming composition and envelope are not integral and at least some of the foaming composition is added to the envelope through a fitment port as shown in FIGS. 6 and 8. In still other embodiments, the envelope is modular and able to be separated into sections along perforations or the like. FIGS. 9A and 9B illustrate such a modular envelope package.

[0055] The envelope may be made of any of a variety of plastic polymers, such as polyethylene, polyester (e.g. Mylar), nylon or other polymeric material. In other embodiments, the envelope may contain intumescent materials to retard flame. In other embodiments, the envelope may be made of a bio-based material such as polylactic acid.

[0056] FIG. 3A illustrates an integral large volume seal 110 comprising an envelope 116 having a front side 116A and a back side 116B (not seen in FIG. 3A), and an activation trigger 118. The envelope 116 has a height, H, a width W, and potentially a depth, D, (not illustrated in this view). The activation trigger 118 is shown near a centerline 120 along the width W, dividing the envelope into a right side 116R and a left side 116L. In some embodiments, portions of the front side 116A may be fused to the back side 116B as shown at areas 122 to create some structure to the envelope, as is described in more detail in connection with FIG. 6. The envelope may include flanges or straps 124 near its outer edges for fastening the envelope to a substrate such as a joist. Staples, nails screws or any other fastener may be driven through the strap 124 to secure the envelope 116 to the substrate.

[0057] FIG. 3B is an enlarged and partly cut-away view of the activation trigger 118. In this embodiment, the activation trigger 118 resembles a dual barreled syringe, as is sometimes used with epoxies. Hollow syringe barrels 126 extend downward from a mounting plate 128 that is fused or sealed to the wall of the envelope 116, such that the barrels 126 are in the interior of the envelope 116 between front side 116A and back side 116B. With common two-part foaming compositions, each barrel contains one part of the foaming composition 130. At the bottom of the syringe barrels 126 are lightweight release seals 132 that prevent the components of the foaming compositions 130 from touching each other until activated. Below the release sealsthat is, further toward the interior of the envelope 116the two barrels 126 merge in a Y-shape junction 134, and then continue into a static mixer 136 before emptying into the envelope interior.

[0058] External to the envelope 116 at the mounting plate 128, plungers 138 extend into each syringe barrel 126, and terminate with a face 140 sealed against the inside of the syringe barrel with a suitable seal such as an O-ring 142. At the top, the plunger includes a pressure pad 144, or preferably a common pressure pad 144 links all plungers so they may be depressed simultaneously. To prevent premature activation during shipping and storage, a protective sheath 146 or cylindrical tube may be inserted between the underside of pressure pad 144 and the mounting plate 128 so that the plungers 138 cannot be inadvertently depressed until the protective sheath 146 is removed. Other embodiments of activation triggers 118 are described later, and would be equally suitable.

[0059] In use, the envelope 116 is installed in place in a large gap and optionally secured there using fastening straps 124. The protective sheath 146 is removed, and the plungers 138 are depressed into the syringe barrels 126, increasing the pressure until the release seals 132 rupture and the foaming compositions 130 begin to pass through the junction 134 and mix in the static mixer 136. As the components of the foaming composition mix, the foaming reaction is initiated and the foam begins to expand the envelope 116 to seal the large gap into which the envelope was installed.

[0060] Static mixers are well known in the industry and require little additional description. Many operate by the principles of flow division (repeated stream splitting) and/or radial mixing (rotational circulation). Others operate by principles of turbulence or tortuous path flow. All are designed to blend two or more separate fluid mixtures into a more homogeneous product. Some static mixers are linear or in-line (FIGS. 3B, 5A and 5B) while others are matrix based (FIG. 8). Any static mixer, regardless of its principle of operation, may be used in the invention provided it affords sufficient mixing of components of the foaming composition to initiate a suitable foaming reaction for the size of the envelope. The static mixer may be part of the envelope system itself, as in the embodiment described above, but in other embodiments described herein the static mixer may be part of a delivery device instead.

[0061] Several typical installation methods are now described with reference to FIGS. 4, 5, and 6. FIG. 4A illustrates an exterior wall, essentially the same as FIG. 1, so parts described there are given identical reference numerals and are not described again here. In FIG. 4A, the large gaps 10, 11 are evident in the interjoist areas adjacent the band joist 20, 40. Two integral large volume sealing devices 110 are shown between the subfloor 22 and the ceiling 52. Each integral sealing device 100 comprises an envelope 116 and an activation trigger 118. In FIG. 4A, the envelope right and left sides 116R and 116L have been rolled about the centerline axis 120 (see FIG. 3) to form a small diameter cylindrical bundle. A hole 114 is made in the subfloor and a similar hole 122 is made in the ceiling 52 near the wall stud 26 (or drywall 30). The bundled sealing device 110 is inserted through the small holes 114, 122 and into the large gaps 10, 11 respectively. When the mounting plate 128 is nearly in the hole 114, 122, the activation trigger 118 is depressed and the integral sealing device 110 is pushed the reset of the way into the hole so that the top pressure pad 144 is within and optionally fills and seals the holes.

[0062] As the foam expands, the envelope 116 unrolls and expands until the sides of the envelope begin to approach the joists 18, 38 on either side as well as the band joists 20, 40 on a third side. The envelope 116 expands up and down as well to occupy the large gap. As shown in FIG. 4B, the envelope 116 at the ground floor level is nearly fully expanded to contact and seal against the sill plate 16 and the subfloor 22, as well as the band joist 20 and flooring joists 18. As noted earlier, the plunger pressure pad 144 may seal the hole 114 or another sealant/cover may be installed and the flooring or carpeting (not shown) may be replaced over the hole 114. The envelope at the upper story floor is also shown in its nearly fully expanded state, pressing against the band joist 40, flooring joists 38, the subfloor 42 and the top plate 14 or ceiling 52. Following installation, the hole 122 may easily be concealed with crown molding 145 or with joint compound or plaster for refinishing and painting. Although only one interjoist gap is illustrated, it is to be understood that many will occur along any given wall since joists are generally placed on 16 inch or 24 inch centers. The integral package 110 is used for each such interjoist gap 10, 11 to seal and insulate the large gap.

[0063] The shape and dimension of the integral seal 110 may be made specific for the site and installation method. For example, in the installation described above with respect to FIGS. 4A and 4B, the height H of the envelope 116 may be 8, 10, 12 or more inches to correspond to the height dimension of the joists. Envelope 116 may have a width W of from 14 to about 24 inches depending on the interjoist spacing and a depth D of from about 2-4 inches up to about 8-12 inches. However, these dimension ranges are specific for installation through a floor or ceiling as described. Other dimensions are suitable for other installations.

[0064] For example, in FIG. 5A, an alternate installation method is shown. The integral seal 110 is similar to that described above. However, in this method, a hole is made in the band joist 20 from the exterior. The device 110 with rolled envelope 116 is inserted into the interjoist gap, the activation trigger 118 is depressed and the foaming begins to expand to fill the envelope 116 and to press against the joists 18, the sill plate 14, the band joist 20 and the subfloor (not shown in this view). For this installation, the width W of envelope 116 corresponds to the interjoist dimension as before, but, since it is installed from the side rather than the top or bottom, the depth dimension correlates to the range given above for joist heights (e.g. 8, 10, 12 or more inches) and the height dimension H of the envelope 116 corresponds to the range described above for depth.

[0065] An external plunger has been described above as one means for triggering the foaming reaction. However, an activation trigger as used herein encompasses any mechanism that can be operated from outside the envelope to initiate a foaming reaction inside the envelope. Thus activation triggers may operate one or more of a wide variety of physical principles such as: (1) mechanical motion, such as pulling, pushing, or leverage; (2) pressure differentials, such as air pressure from compressed air, manual pressure, pinch rollers, etc; (3) invisible waves, such as sound waves (e.g. ultrasound); electromagnetic waves (light, IR, UV, X-ray, microwave, heat, etc); and (4) electrical stimulus, such a voltage potential, shock, etc.

[0066] An alternative activation trigger 218 is shown in FIGS. 7A and 7B. Two layers 219A and 219B of a flexible foil or polymeric plastic are fused together along the edges 220 to create an interior 222. For two-part foaming compositions, the interior 222 may be divided into two compartments 222A and 222B by fusing a central pillar 224 as well. The compartments 222A and 222B may be tapered as shown by fusions 226 to a junction area 234 where the layers are joined and sealed to a static mixer 236. Lightweight release seals 232 keep the compartments 222 closed to the junction 234 until use. The outlet 238 of the static mixer is open to the interior of an envelope seal (not shown in FIG. 7).

[0067] Prior to use and fusing the layers 219, the components of a foaming composition are sealed into the compartments 222. In use, pressure is applied to the flexible layers 219, such as for example by a pinch roller 240, to force the components of the foaming composition to rupture the release seals 232 (FIG. 7B) and to push the foaming composition into the junction 234 and then to static mixer 236. Eventually, the mixed foaming composition 239 is forced out the outlet 238 into the interior of the envelope where it begins expanding the envelope as described above. The pressure applied to activate the trigger 218 may also come from manual manipulation of the trigger 218 or from a source of compressed air.

[0068] The trigger 218 will be associated with an integral package envelope like 116 with at least the outlet 238 being sealed inside the envelope interior. Alternatively, the entire static mixer 236 or even the entire trigger assembly 218 may be within the envelope in some embodiments. It can still be activated from the exterior by applying sufficient pressure to the trigger. In such cases, it may be desirable to include delayed catalysts in the foaming composition so that the foaming reaction can be triggered on a bench prior to installation, and the delay allows sufficient time to install the envelope in the gap before the foaming reaction gets underway.

Other Embodiments and Variations

[0069] In general, the integral-type package 110 described above is particularly well suited for retrofit applications, although it may also be used in new construction. It is easy to use, even for the do-it-yourself population, since the prescribed quantity or dose of a foaming composition is self contained within or adjacent the envelope and can be activated from outside the envelope to initiate the foaming reaction. However, the additional costs associated with the triggering device make this a more expensive choice for the professional contractor doing bulk insulation, particularly in new construction where interjoist gaps and other gaps may be more accessible. For these users and applications, another package may be preferable, although either type package may be used in either application. An alternative embodiment comprises an envelope having, instead of a foam-filled activation device, a port or fitment through which bulk foaming composition may be delivered to the envelope interior. A delivery device for injecting bulk foaming composition is dimensioned to attach to the fitment port and to pump bulk foaming composition into the envelope. To distinguish this from the integral package embodiment, this embodiment is referred to herein as the fitment embodiment or bulk embodiment.

[0070] The bulk embodiment is described below in connection with FIG. 5B, which illustrates a foundation 12 on which sits a sill plate 14. As before, the sill plate 14 supports band joist 20 and flooring joists 18 which, in turn, support subfloor 22. However, when the building has an accessible crawlspace or basement below the flooring joists 18 and the joists are exposed, it is possible to install envelope seals 216 into the interjoist space from below without making any holes in the subfloor 22 or band joist 20. Consequently, envelope 216 may comprise an integral package seal, containing its own foaming composition and an activation trigger, or it may comprise a bulk embodiment having a port or fitment through which bulk foaming composition can be injected into the envelope. Fitment port 217 is shown in FIG. 5B. Fitment ports generally are described in more detail below.

[0071] FIGS. 6A and 6B illustrate another embodiment of an envelope seal 310 for sealing a large volume. The envelope seal 310 is similar to the envelope seal of FIG. 3A, but it lacks an activation trigger. It comprises an envelope 316 having a front and back side, a height H2, a width W2, and optionally a depth D2. It may comprise flanges or straps 324 for securing the envelope to a substrate, such as flooring joists 38. As with the embodiment of FIG. 3A, the envelope 316 may comprise areas 322 where the front and back walls or panels of the envelope are fused together. Such fused areas help give shape and strength to the expanded envelope as seen in FIG. 6B. As before, when the envelope 316 is expanded, it seals against the joists 38, the top plate 34 or ceiling 52, and the subfloor 42. Notably, no band joist is shown, as this Figure illustrates the wall extension type of installation to fill volumes 61, 62 as described above in connection with FIG. 2. It should be appreciated, however, that this embodiment is not limited to installation for this type of gap and is equally well suited to band joist or other large gaps.

[0072] Instead of an activation trigger, this embodiment is the bulk or fitment type and has a fitment port 317 on the exterior face of the envelope 316 which communicates to the interior. Fitment ports may vary, but a simple design consists of a hollow cylindrical piece of plastic or polymer with a flange that allows it to seal against the envelope (see also FIG. 8). The main constraint is that fitment ports can, with or without the use of adapter sleeves, tightly interact and seal with a nozzle or barrel of a bulk foaming composition delivery device. For example, a nozzle of a delivery gun may be cylindrical, and the fitment is a hollow cylinder dimensioned to receive the nozzle and tightly seal against it so that bulk foaming composition is delivered to the interior of envelope 316 without leaking or spilling. A slight tapering of the fitment wall or the device nozzle may enhance the seal. Fitment port 317 may contain a valve (not shown) for allowing entry but preventing egress of bulk foaming composition; and it may contain deflectors or baffles (not shown) for directing the injected foam to various areas of the interior.

[0073] When expanded, the envelope 316 includes tubular ribs 315 separated by the fused areas 322 as best seen in FIG. 6B. This arrangement provides additional strength and, by limiting depth D2, urges the expanding envelope outward against its substrates (e.g. subfloor 42, top plate 34 and flooring joists 38) for a better seal instead of allowing the foam to expand the envelope laterally into the interjoist spaces. Additionally, in any of the embodiments described herein, the envelope may include leak pores or perforations (described below in connection with FIG. 9B) around the perimeter of the envelope. Such leak pores allow small amounts of foam to seep out of the interior to ensure a good seal against the substrate all around the envelope.

[0074] In the simple fitment port 317 described above, the foaming compositionif a two-part compositionmust be mixed prior to entering the fitment port 317. This is also true of traditional two-part spray foams so existing delivery devices are generally capable of drawing up components from two sources, pumping them to a location, and mixing them in a delivery gun just before they are applied to a site. Such delivery guns are known in the art and are suitable for use to inject foaming compositions into envelopes with simple fitment ports like 317. The nozzle of the delivery device is generally cylindrical and can be inserted into the cylindrical fitment port. Adapters may be used if needed to ensure tight fits with no leakage of foaming composition. Simple friction fits are generally sufficient, although more complex bayonet mounts or screw mounts are possible and within the purview of the invention.

[0075] FIG. 8 shows in cross section an alternate fitment port 417 that does not require the components of the foaming composition to be mixed prior to entry into the fitment port. Thus it keeps delivery gun nozzles free of mixed foaming composition, rendering them easier to clean after use. Fitment port 417 comprises a cylindrical flanged plastic part 410 fused to one side (416A) of an envelope 416 of construction similar to that previously described. Flanged part 410 consists of an annular or tubular wall 412 hollow throughout, molded to a flange 414 to provide a base for fusion to the exterior wall of envelope front 416A. Envelope wall 416A includes an opening or hole 420 in registry with the hollow core of the annular wall 412. On the interior side of envelope wall 416A a fibrous matrix 422 is fixed in the area where the flanged part 410 opens through hole 420 into the interior 413 of the envelope 416.

[0076] The fibrous matrix may be made of polymer or inorganic fibers and may be bonded fibers or woven or non-woven fibers. It will be sized appropriately for the envelope size and quantity of foaming composition, to provide a mixing effect for foaming composition components that are injected through the fitment port into the matrix. Baffles or diverters (not shown) may be employed to direct foaming composition through a sufficient tortuous path of the fibrous matrix to effect the necessary mixing. In particular, an impervious barrier layer 424 of polyethylene or the like may be applied to the face of the fibrous matrix that is furthest from the front wall 416A. This helps control the flow path of the foaming composition to direct it perpendicular to the flow through the fitment wall 412, so that it flows through more of the matrix and improves mixing. Additionally, the matrix 422 provides some separation of the back wall 416B from the front wall 416A.

[0077] FIG. 9A illustrates a further embodiment of an envelope seal 510 produced in bulk. Individual envelopes 516A and 516B are shown attached together at perforation tear line 520, which may also include a fused seam border along the perforation line. In likewise manner, envelope 516B is attached to envelope 516C, etc as the roll 518 to the left in FIG. 9A suggests. Each envelope on the roll 518 has a height H3 and a width W3, and optionally a depth D3, not shown. The width W3 corresponds to the spacing between perforation lines 520. Depending on the embodiment, the front and back side may be fused in areas 522 to create ribs 515 as described in connection with FIG. 6. Lo-rise fitment ports 517 may be added for the purpose if injecting a foaming composition or component(s) thereof. One or two fitment ports 517 are shown per envelope, for example. They may be similar to other fitment ports described, except that, for producing a rolled product, the depth of the port should be minimized to reduce bulk. Thus, low-rise fitments are preferred.

[0078] This roll product is easily manufactured in long webs of intermittently fused layers, and rolled for shipping and storage. In use, one simply unrolls the web, separates an envelope along a perforation line, secures it to the desired substrate and connects a source of foaming composition to the fitment through a delivery device as described above. As with prior embodiments, the envelope 516 may be made in standard heights and width to fit conventional gap areas. Alternatively, by spacing the perforation lines 520 closer together (more frequently), the roll may be produced with fractional widths W3, such that multiple envelopes are used to fill a large volume. This modular approach offers more flexibility in filling gaps of varying sizes. In another variation, the roll may omit the perforation lines 520 and the user simple cuts the envelope to length along any fused area 522. Since the fused seam is no longer present, this variation produces an envelope that is open at the cut end along the top and bottom. This area may be fused manually, or it may be left open so that foam may extrude from this opening to further seal corner areas of a large gap and to further secure the envelope in position attached to the substrate such as a joist.

[0079] An alternative modular embodiment is illustrated in FIG. 9B. In this embodiment the envelope 615 is designed to be modular so as to fit irregular spaces better. One example of such an irregular space is where a duct or pipe extends through a band joist, as is the case, for example, with a dryer vent or a high efficiency furnace air intake and exhaust. Each envelope 615 is made up of a plurality of smaller segments 616 that are attached together much like a quilt. In reality, during manufacturing, a web of envelopes is manufactured and divided into segments 616 by fusing a seam 618 in a machine direction, and a seam 619 in a cross-machine direction, although these machine directions are arbitrary to the final orientation of the envelope 616 shown. Within the width of each fused seam 618, 619 a perforation line 620 is inserted, so that a portion of the segments 616 can be separated from the others in order to fit an irregular space.

[0080] In the specific embodiment illustrated in FIG. 9B, six segments 616A-F are removed from the bulk web in a 23 matrix in order to fill a volume such as a joist gap. However, to fit the envelope seal 615 into an irregular volume in which a pipe 640 extends, the upper center segment 616B (shown in phantom) is separated from the other 5 to make room for pipe 640. Separated in this context encompasses complete removal of the unused segment as well as partial removal by making tears or cuts along perforations or not to make room for the obstruction that makes the space irregular. For example, segment 616B might be separated along the perforations between 616B-616C and between 616A-616B, and hinged downward along the perforation seam 618 between segments 616B and 616E. Alternatively, a cut may be made down the center of absent segment 616B, and the 616B-616E perforation may be separated so that each half opens like two doors folding behind segments 616A and 616B. Finally, segment 616B may be separated from all three remaining sides and removed, as is the case represented in FIG. 9B.

[0081] Envelope segments 616 all include a fitment port 617 as was described previously for injecting a foaming composition to the interior of envelope. Since the volume of each segment is relatively small, it may be useful to provide a keying means to inform the delivery device how much volume to inject. RFID tags 630 can be used to convey this information to the delivery device.

[0082] In some embodiments, it may be desirable to provide strategic leak pores in the envelope. In FIG. 9B these leak pores take the form of arcs 632 that represent small holes punctured in the envelope wall. As with the cut end of the envelope 516 described above, leak pores like this allow the foam to extrude in a controlled fashion to further seal the gap and secure the envelope in place. In FIG. 9B, foam 635 is shown extruding from the right side of segment 616A and from the top of segment 616E to further seal the space around the pipe 640. Once the foaming composition is injected and begins to expand, it would also extrude from all the other pore or arcs 632 as represented by certain arrows 637, but not shown as foam. The amount and type of foam used is desirably chosen so that these strategic leak pores further seal the gap area, further secure the envelope in place and potentially even add insulation value and strength to the envelope. As other segments 616 are filled (E.g. 616C and 616F) they too would ooze or extrude foam via the arcs 632 to complete the seal of the gap around the pipe 640, to further secure the envelope in place, and to further strengthen and insulate the seams 618, 619.

[0083] The choice of size of the segments is simply one of tradeoffs. The smaller the size of each segment, the greater the flexibility in shaping the envelope to fit an irregular volume. The concept is much that same as resolution of a monitorthe more pixels, the higher the resolution of the image. The tradeoff is that there are more ports to fill with even smaller quantities, thus contributing to labor costs. Balancing this tradeoff is within the purview of those skilled in the art to design reasonable flexibility with minimal labor time and expense. For typical interjoist gaps, the number of segments may range from 1 to about 24, more likely from about 1 to about 12 segments. However, the number is not critical and will certainly vary for other types of large volumes.

Foaming Compositions

[0084] The foams that may be used within the envelope may be of any of the known types of foaming compositions, including both open and closed cell foams. Generally speaking, foaming compositions include two reactive film-forming ingredients; a structure, scaffold or skeleton former; and a blowing agent. Other additives may be present of course as is taught in connection with known foaming compositions. The foams may be one-part, but reactive components must be kept separated until ready to initiate the foaming reaction. An easy way to keep the reactive components separated until desired is to package them in separate compartments or containers, which gives rise to description in the literature of two-part foaming compositions. Any of the one-part or two-part foams described in any of the following references, each of which is incorporated in its entirety by reference, can be used with the present invention. [0085] U.S. Pat. No. 5,444,099 to Abe et al., U.S. Pat. No. 4,945,120 to Kopp et al. and U.S. Pat. No. 3,984,360 to Galbreath et al. disclose polyurethane foams. [0086] U.S. Patent Publication Nos. 2008/0161430; 2008/0161431; 2008/0161433; 2008/0161432; 2009/0111902; and 2010/0175810 to Korwin-Edson et al. disclose latex foams. [0087] U.S. Patent Publication No. 2006/0047010 to O'Leary discloses a polyisocyanate prepolymer foaming composition. [0088] U.S. patent application Ser. No. 12/875,640, filed Sep. 3, 2010 and 61/421,680 filed Dec. 10, 2010 to O'Leary disclose non-aqueous based foaming compositions that will nevertheless foam at room temperatures.

[0089] The availability and low cost of isocyanate/polyol reagents that make low density polyurethane foams are well suited for use with the present invention. They are well tested and understood in the industry and make low density open cell foams in the 0.25 to 3 pound per cubic foot (pcf) range. While these foams have been avoided for spray applications, due to health concerns related to inhaling dangerous vapors, these dangers are removed or minimized in the present invention for two principle reasons. First, the foam is not sprayed or atomized so that it is more difficult to inhale. Even in the embodiment where a delivery gun or device is used, the foam is injected directly into the interior of the envelope and does not generally escape to the atmosphere. Second, the foam is largely self-contained within the envelope. Although some embodiments have strategic leak pores that allow some foam to escape, these are placed at the perimeters of the envelopes so that the foam has time to polymerize and set up before leaking to the exterior. In this way no toxic monomeric NCO's are likely to escape.

[0090] The foaming composition may contain other optional ingredients, in either or both of an A-side and B-side when two-part foams are used. Such optional ingredients may include catalysts, a nucleating agent, coagulation agents, foam promoters, opacifiers, accelerators, foam stabilizers, dyes (e.g., diazo or benzimidazolone family of organic dyes), color indicators, gelling agents, flame retardants, intumescents, biocides, fungicides, algaecides, fillers (aluminum tri-hydroxide (ATH)), and/or blowing agents. It is to be appreciated that a material will often serve more than one of the aforementioned functions, as may be evident to one skilled in the art. The additives are desirably chosen and used in a way such that the additives do not interfere with the mixing of the ingredients, the cure of the reactive mixture, the foaming of the composition, or the final properties of the foam. Other optional additives can be between 0 and 10% of the final formulation.

[0091] Some specific flame retardants include: Triethyl Phosphate TEP, Tributoxyl Ethyl Phospahte (TBEP), Tri-isobutyl Phosphate (TIBP), Tris (2-Chloroisopropyl) Phosphate (TCPP), Tris (1,3-dichloro-2-propyl) Phosphate (TDCP), Triphenyl Phosphate (TPP), Tricresyl Phosphate (TCP), Triphenyl Phosphite, Triphenyl Phosphine, Tris (2-chloroethyl) Phosphate (TCEP), 1-Phenyl-3-Methyl-5-Pyrazolone (PMP), AcetoacetanilideAAA, and Phosphate Flame Retardants BDP and RDP.

[0092] As mentioned earlier, for some embodiments it may be desirable to delay the onset of the foaming reaction once the trigger is activated. Some types of activation triggers may be used after the envelope is installed, while other types may be used on a bench or surface just prior to installation. In the latter case, delaying the onset of foaming to allow time to install the envelope may be desired. Certain modified catalysts can do this. Notably, to create a delayed action, formic acid can be added to either a gel catalyst such as TEDATriethylene amine or DBTDLDibutyltindilaurate; or to a blowing catalyst such as BDMAEEbis(2-dimethylaminoethyl ether) or DMDEE2,2 Dimorpholinodietyl ether.

[0093] In exemplary embodiments, the foams of the present invention, as well as the components thereof, meet certain performance properties, or Fitness for Use (FFU) criteria, both chemical and physical. In particular, desired criteria or FFUs that the inventive foam should meet are set forth in the table below:

TABLE-US-00002 Chemical Criteria Physical Criteria The foam should adhere to various The foam weight should be between about materials such as wood, metal, 0.2 and about 4.0 pounds per cubic foot concrete and plastic The foam should be fluid enough to be The chemical constituents should be sprayed either at room temperature or by safe. Even though isocyantates may heating (viscosity of <10,000 cP at a high be used, the dangerous monomeric shear rate) NCOs are not introduced or atomized The foam should not sag or fall in the cavity into the air where they can be inhaled; The foam should fill in cracks and crevices even if they extrude from the leak or be used to coat the cavity with an air pores, they are substantially barrier polymerized by then. Ideally, the cell structure of the foam (closed The foam may be chemically foamed vs. open) should be open cell structure to through the use of a blowing agent or provide appropriate material density it may be mechanically foamed with a properties and avoid volatile blowing agents gas The foam should have a thermal resistance The installer of the foam should be (R-value) of at least 3.0 Fft.sup.2h/BTU per inch able to work with the material without The foam should be non-sagging and non- any specialized personal protective dripping (i.e., fire retardant) during a fire equipment (PPE), such as a The foam should not corrode metal objects breathing apparatus, although such as screws, nails, electrical boxes, and chemical goggles, dust mask, and the like gloves are acceptable Air infiltration should be negligible (ASTM The foam should not lend itself to E283-04) (spec 0.4 cfm/sq ft) molding or fungus growth (ASTM Water vapor infiltration should be greater C1338) than 1 perm or 5.72 10.sup.8 g/Pa-s-m.sup.2 The foam should not contain a food The foam should have low or no odor. source for insects or rodents There should be a minimum shelf life of the un-reacted constituents of 9 months.

Methods and Process

[0094] The final foamed product becomes cured to the touch within minutes after application, and hardens within about 1 to 6 minutes. In foams intended for use as insulating materials, the resulting resistance to heat transfer, or R-value, is desirably from about 3.5 to about 8 per inch. In certain uses, the foamed product has an integral skin that restricts the passage of air but permits the passage of water vapor.

[0095] Another advantage of the foams of the present invention is the safe installation of the foam into cavities. Because the foams do not release any harmful vapors into the air when applied or sprayed, the inventive foams reduce the threat of harm to individuals working with or located near the foam. In addition, the application of the foams is more amenable to the installer as he/she will not need to wear a special breathing apparatus during installation.

[0096] Another advantage of the inventive foams is that it can be used in the renovation market, as well as in houses that are occupied by persons and/or animals (e.g. renovation market). Existing spray polyurethane foams cannot be used in these applications because of the generation of high amounts of free isocyanate monomers that could adversely affect the occupants of the dwelling. As discussed above, exposure of isocyanate monomers may cause irritation to the nose, throat, and lungs, difficulty in breathing, skin irritation and/or blistering, and a sensitization of the airways.

[0097] The invention of this application has been described above both generically and with regard to specific embodiments, although a wide variety of alternatives known to those of skill in the art can be selected within the generic disclosure. The invention is not otherwise limited, except for the recitation of the claims set forth below.