INSULATION BLOCK FOR A CORNER STUD CAVITY

Abstract

A corner insulation block for installation in a corner stud cavity of a wall system of a structure is disclosed. The corner insulation block includes a foam body in the shape of a rectangular prism. The foam body of the corner insulation block includes a width, a thickness, and extends a length between a first end and an opposite second end. The corner insulation block includes a plurality of cutting guides at one of the first end or the opposite second end of the foam body. Each of the plurality of cutting guides is spaced from an adjacent one of the plurality of cutting guides.

Claims

1. A corner insulation block for installation in a corner stud cavity of a wall system of a structure, the corner insulation block comprising: a foam body in the shape of a rectangular prism, the foam body including a width, a thickness, and extending a length between a first end and an opposite second end; and a plurality of cutting guides at one of the first end or the opposite second end of the foam body, each of the plurality of cutting guides being spaced from an adjacent one of the plurality of cutting guides.

2. The corner insulation block of claim 1, wherein the foam body comprises a closed-cell foam body.

3. The corner insulation block of claim 1, wherein the foam body comprises a unitary piece of closed-cell foam.

4. The corner insulation block of claim 1, wherein the plurality of cutting guides includes a first cutting guide and a second cutting guide.

5. The corner insulation block of claim 4, wherein the first cutting guide and the second cutting guide each comprise a score line.

6. The corner insulation block of claim 5, wherein each score line extends partially or fully about a perimeter of the foam body of the corner insulation block.

7. The corner insulation block of claim 1, wherein the first cutting guide is spaced about 12 inches from the first end or the opposite second end of the foam body, and the second cutting guide is spaced about 12 inches from the first cutting guide.

8. The corner insulation block of claim 1, wherein the width of the foam body is about 5.5 inches, the thickness of the foam body is about 4 inches, and the length of the foam body is about 9 feet 9 and inches.

9. The corner insulation block of claim 1, wherein the width of the foam body is about 5.5 inches, the thickness of the foam body is about 4 inches, and the length of the foam body is about 11 feet 9 and inches.

10. A wall system of a structure, comprising: one or more studs and one or more drywall backers arranged in a space between sheathing and drywall of the wall system at a corner of the structure to form a corner stud cavity; and the corner insulation block of claim 1 installed within the corner stud cavity.

11. The wall system of claim 10, wherein the corner insulation block fills 90% or more of a volume of the corner stud cavity.

12. The wall system of claim 10, wherein the corner is an exterior corner of the structure.

13. The wall system of claim 10, wherein the corner stud cavity is formed between at least two studs and at least one drywall backer.

14. The wall system of claim 10, wherein the foam body of the corner insulation block comprises a unitary piece of closed-cell foam that extends between a floor and a ceiling of the structure.

15. The wall system of claim 10, wherein the structure is a residential home.

16. A method for insulating a corner stud cavity of a structure, comprising: providing a corner insulation block, comprising: a foam body in the shape of a rectangular prism, the foam body including a width, a thickness, and extending a length between a first end and an opposite second end; and a plurality of cutting guides at one of the first end or the opposite second end of the foam body, each of the plurality of cutting guides being spaced from an adjacent one of the plurality of cutting guides; sizing the corner insulation block to the corner stud cavity; and installing the corner insulation block in the corner stud cavity.

17. The method of claim 16, wherein sizing the corner insulation block to the corner stud cavity further comprises: determining a length of the corner stud cavity; comparing the length of the corner stud cavity to the length of the corner insulation block; if the length of the corner insulation block is greater than the length of the corner stud cavity, selecting one of the plurality of cutting guides corresponding to the length of the corner stud cavity; and cutting the corner insulation block along the selected one of the plurality of cutting guides.

18. The method of claim 17, wherein the plurality of cutting guides include a first cutting guide and a second cutting guide, the second cutting guide being spaced about 12 inches from the first cutting guide, the method further comprising: selecting one of the first or the second cutting guides corresponding to the length of the corner stud cavity; and cutting the corner insulation block along the selected first or second cutting guide.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:

[0019] FIG. 1A is a diagrammatic plan view of a corner of a house, illustrating a conventional corner stud cavity;

[0020] FIG. 1B is a view similar to FIG. 1, illustrating a California Corner and the resultant corner stud cavity;

[0021] FIG. 2 is a diagrammatic plan view of an exemplary corner of a structure, illustrating a pair of corner insulation blocks arranged in the corner stud cavity in accordance with one embodiment of the invention;

[0022] FIGS. 3A and 3B are perspective views of a section of an exemplary corner of a structure, illustrating the pair of corner insulation blocks arranged in the corner stud cavity in accordance with one embodiment of the invention;

[0023] FIG. 4A is a perspective view of a corner insulation block in accordance with another embodiment of the invention;

[0024] FIG. 4B is a plan view of the corner insulation block of FIG. 4A installed in a corner stud cavity of a structure;

[0025] FIG. 4C is a partial cross-sectional elevation view of the corner insulation block of FIG. 4A installed in corner stud cavity of a structure;

[0026] FIGS. 5A and 5B illustrate a corner insulation block in accordance with another embodiment of the invention; and

[0027] FIGS. 6A and 6B illustrate a corner insulation block in accordance with another embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0028] According to various embodiments of this invention, a corner insulation block for a corner stud cavity 5 of a structure 2 (e.g., home or building) is provided. The corner insulation block is configured to be installed in the corner stud cavity 5 to generally fill the void that forms the corner stud cavity 5 to thereby provide superior insulation in what is typically a challenging location to insulate, as set forth above. As described in more detail below, the corner insulation block may comprise either a single square or rectangular beam of material or multiple square or rectangular beams of material. The configuration of the corner insulation block may be determined by the shape and size of the corner stud cavity 5 to be insulated, for example. To that end, the corner insulation block is shaped and sized to fill a majority of, if not the entire, corner stud cavity (i.e., void) 5, thereby creating an effective insulation barrier for the corner 1 of the structure 2. These and other benefits of the invention will be described more fully below.

[0029] Referring now to FIG. 2, a pair of corner insulation blocks 10 are shown installed in a corner stud cavity 5 at an outside or exterior corner 1 of a structure (e.g., a building or house) 2 in accordance with one embodiment of this invention. As shown, the outside corner 1 of the structure 2 includes two studs 4 and one drywall backer 3 to which sheathing 12 (for exterior) and drywall 14 (for interior) of the structure 2 may be attached. For example, the studs 4 and drywall backer 3 may have a width of 6 inches and a thickness of 2 inches (i.e. a 26). The corner 1 of the structure 2 may include overlap sheathing 16 and tape 18 as will be understood by one of ordinary skill in the art.

[0030] In the embodiment shown in FIG. 2, each corner insulation block 10 is formed from a thick, rigid foam and is generally formed or cut to a width of about 5.5 inches, a thickness of about 2 inches, and a length corresponding to the height of the corner stud cavity 5. Each corner insulation block 10 defines a foam body in the shape of a rectangular or square prism. In the embodiment shown, the corner insulation blocks 10 are configured to be stacked and sandwiched within the corner stud cavity 5 between the studs 4 and the drywall backer 3, as shown. The corner insulation bocks 10 are stacked and arranged such that the length of each corner insulation block 10 extends generally parallel to a length of the studs 4 and drywall backer 3. Depending on the size of the corner stud cavity 5, fewer or more corner insulation blocks 10 may be used. In either case, the corner insulation blocks 10 are configured to fill or occupy 90% or more of the volume within the corner stud cavity 5. To that end, the corner insulation blocks 10 may be formed or cut to the appropriate size as required to fill the corner stud cavity 5. A framer may arrange the corner insulation blocks 10 as shown in FIG. 2 while framing the wall panels of the structure 2, for example.

[0031] The corner insulation blocks 10 may be formed from a rigid, closed-cell foam such as expanded polystyrene (EPS), extruded polystyrene (XPS), or polyisocyanurate, or any other suitable foam that provides high thermal resistance. Closed-cell foams are dimensionally stable and rigid, allowing the blocks to be inserted into the corner stud cavity 5 without collapsing or losing shape. Closed-cell foams also provide higher thermal resistance per unit thickness and resist moisture absorption, ensuring long-term insulation performance in the wall cavity. By contrast, for example, open-cell foams are softer, less rigid, and more permeable to moisture, making them undesirable for use as discrete insulation blocks in this application.

[0032] FIGS. 3A and 3B are perspective views of an exemplary section of a corner 1 of a structure 2 including a pair of corner insulation blocks 10 arranged in the corner stud cavity 5. As shown, the corner insulation blocks 10 are cut to the appropriate size as required to fill the corner stud cavity 5.

[0033] The rigid foam used to make the corner insulation blocks 10 may only be available in large sheets measuring 4 feet by 8 feet, for example. As a result, the large sheets of foam may need to be cut to the appropriate size required for the corner insulation blocks 10, such as at the job site. Because these foam sheets are typically 2 inches thick, they may be too thick to cut easily with a standard handheld retractable razor blade. As a result, it is difficult to cut the sheets on-site into corner insulation blocks 10 that are sized to fully occupy the corner stud cavity 5. Even when the sheets are cut to size, they often lack clean edges. Additionally, if a framer is installing corner insulation blocks 10 on the outside corner 1 of a structure 2 that is taller than 8 feet, four pieces of 5.5-inch wide foam need to be cut: two pieces 8 feet long (matching the length of the foam board) and two additional pieces to fill the remaining height of the corner stud cavity 5. To that end, this problem is becoming more widespread, as most new construction homes feature wall systems that are 9 feet or taller on the first floor, and many have 9-foot walls on the second floor.

[0034] Turning now to FIGS. 4A-4C, where like reference numerals represent like features compared to the embodiment of the corner insulation block 10 described above with respect to FIG. 2, a corner insulation block 20, otherwise referred to as a foam corner block (FCB), is show in accordance with another embodiment of the invention. The primary difference between the corner insulation block 20 of this embodiment and the corner insulation block 10 of the previously described embodiment is that the corner insulation block 20 is a single, pre-formed foam piece configured to fill 90% or more of the volume within the corner stud cavity 5. The corner insulation block 20 resolves the issue of having to cut the corner insulation blocks 10 from large sheets of material on a job site, described above. To that end, the corner insulation block 20 may be supplied to the job site as a ready-to-use item, and may be supplied with the lumber, for example (no differently than a roll of Tyvek house wrap).

[0035] As shown in FIG. 4A, the corner insulation block 20 may have a width W of 5.5 inches and a thickness T of 4 inches. The corner insulation block 20 extends a length between a first end 22 and an opposite second end 24, and may be manufactured having a standard length of about 10 feet (e.g., 9 feet 9 and inches). The corner insulation block 20 defines a foam body in the shape of a rectangular or square prism. As shown, the corner insulation block 20 includes an overall or total length L1 of 9 feet 9 and inches, which is appropriate for a 10 foot wall system 26 (FIG. 4C), and thus may generally be referred to as a 10 foot corner insulation block 20. The corner insulation block 20 includes a plurality of cutting guides 28a, 28b at one end 22. The cutting guides 28a, 28b may include physical score lines formed in the foam body, shallow grooves, printed or painted marks, embossed or recessed indicia, or other visual or structural indicators. The cutting guides 28a, 28b may extend partially or fully about the perimeter of the corner insulation block 20. For example, the cutting guides 28a, 28b may extend about the corner insulation block 20 on one side, two sides, three sides, or all four sides of the corner insulation block 20.

[0036] In the embodiment shown, the cutting guides 28a, 28b are in the form of score lines that are located at the first end 22 of the corner insulation block 20. Additionally or alternatively, the cutting guides 28a, 28b may be located at the second end 24. As shown, a first cutting guide 28a is spaced generally about 1 foot (i.e., about 12 inches) from the first end 22 along the length of the corner insulation block 20 and about 8 feet 9 and inches from the second end 24, appropriate for a 9 foot wall system. That is, a length L2 of the corner insulation block 20 as measured from the second end 24 to the first cutting guide 28a is about 8 feet 9 and inches. A second cutting guide 28b may be spaced about 2 feet (i.e., about 24 inches) from the first end 22 along the length of the corner insulation block 20 and about 7 feet 9 and inches from the second end 24, appropriate for an 8 foot wall system. That is, a length L3 of the corner insulation block 20 as measured from the second 24 to the second cutting guide 28b is about 7 feet 9 and inches. Stated differently, the second cutting guide 28b is spaced about 1 foot (i.e., about 12 inches) from the first cutting guide 28a in a direction toward the second end 24 of the corner insulation block 20. The cutting guides 28a, 28b are generally spaced about 1 foot apart from each other along the length of the corner insulation block 20.

[0037] The cutting guides 28a, 28b allow the corner insulation block 20 to be easily cut down to size for various wall systems, such as to fit a 9 foot or 8 foot wall system, as set forth above. In that regard, the one-foot spacing of the cutting guides 28a, 28b is not arbitrary but is critical because it aligns different, reduced lengths of the corner insulation block 20 with standard wall heights (e.g., 8 or 9 feet) used in residential and commercial construction. The spacing of the cutting guides 28a, 28b allows a single stock corner insulation block 20 to be cut precisely to fit these wall systems without waste or additional trimming or cutting efforts. Other spacings, such as 6 inches or 18 inches, would not reliably produce lengths corresponding to standard wall heights, particularly when starting with a corner insulation block 20 with a length corresponding to a standard wall heigh, such as 10 feet, and would undermine certain benefits provided by the invention.

[0038] It will be understood that the corner insulation block 20 may be provided with a length L1 of 12 feet (e.g., 11 feet 9 and inches) with cutting guides 28a, 28b so that it may be cut down to size for an 11 foot or 10 foot wall system. To that end, retail stores and supply houses may only need to stock two different sized corner insulation blocks 20 (10 foot and 12 foot) to accommodate 8 foot, 9 foot, 10 foot, 11 foot and 12 foot wall systems. For example, the corner insulation block 20 may include a first cutting guide 28a spaced about 1 foot from the first end 22, thereby defining a length L2 of about 10 feet 9 and inches as measured from the second end 24 to the first cutting guide 28a, suitable for an 11 foot wall system. A second cutting guide 28b may be spaced about 2 feet from the first end 22, thereby defining a length L3 of about 9 feet 9 and inches as measured from the second end 24 to the second cutting guide 28b, suitable for a 10 foot wall system. The cutting guides 28a, 28b are spaced about 1 foot apart from one another along the length of the corner insulation block 20. In this manner, only two standard sizes of corner insulation blocks 20, namely 10 foot and 12 foot lengths, are needed to accommodate wall systems ranging from 8 feet through 12 feet in height.

[0039] With reference to FIG. 4B, the corner insulation block 20 is configured to be arranged within the corner stud cavity 5 between the studs 4 and the drywall backer 3. The corner insulation bock 20 is arranged such that the length of the corner insulation block 20 extends generally parallel to a length of the studs 4 and drywall backer 3. For example, as shown in FIG. 4C, the second end 24 of the corner insulation block 20 may be arranged adjacent to a bottom plate 29 and sub floor 30 of the structure 2 with the first end 22 of the corner insulation block 10 being arranged adjacent to a ceiling 32 of the structure 2. The single corner insulation block 20 may extend a length between the bottom plate 29 and the ceiling 32 of the structure 2. Stated another way, the single corner insulation block 20 may extend a length between a floor of the structure 2 and a ceiling 32 of the structure 2. Only one corner insulation block 20 is required for each corner stud cavity 5, as shown. The corner insulation block 20 is configured to fill 90% or more of the volume within the corner stud cavity 5. Depending on the height of the corner stud cavity 5 (i.e., wall height) a framer may cut the corner insulation block 20 down to size to fill the void 5 as needed. To that end, the framer may cut the corner insulation block 20 at a cutting guide 28a, 28b, or between cutting guides 28a, 28b.

[0040] FIGS. 4B and 4C illustrate a corner 1 of an exemplary 10 foot wall system 26 of the structure 2 in which the corner insulation block 20 is installed. Various components of house construction, familiar to those skilled in the art, are also depicted in FIG. 4C, including a rim joist 34, plate 36, and concrete foundation 38, for example. The corner insulation block 20 may be installed in the corner stud cavity 5, as shown, by a framer while they frame each wall section of the structure 2 that includes a corner 1. The corner insulation block 20 may be caulked, adhered, or otherwise secured within the corner stud cavity 5 to enhance the air barrier and minimize any airflow through the envelope around the corner insulation block 20. Regardless, the corner insulation block 20 is configured to fit snugly between the framing that defines the corner stud cavity 5, providing a tight seal for optimal insulation. For example, a long screw, such as a GRK long screw commercially available from GRK Manufacturing (Hamilton, OH) may be installed through the corner 1 of the wall system 26 to squeeze the corner insulation block 20 in between the adjacent wall studs 4.

[0041] FIGS. 5A and 5B, where like reference numerals represent like features compared to the embodiments described above with respect to FIGS. 1-4C, illustrate the corner insulation block 20 cut down to size to fit a 9 foot wall system 40. Specifically, the corner insulation block 20 was cut at cutting guide 28a, resulting in the corner insulation block 20 having a length L2 of about 8 feet 9 and inches. FIG. 5B illustrates the corner insulation block 20 installed in the corner stud cavity 5 at an exemplary corner 1 of the 9 foot wall system 40.

[0042] FIGS. 6A and 6B, where like reference numerals represent like features compared to the embodiments described above with respect to FIGS. 1-4C, illustrate the corner insulation block 20 cut down to size to fit an 8 foot wall system 42. Specifically, the corner insulation block 20 was cut at cutting guide 28b, resulting in the corner insulation block 20 having a length L2 of about 7 feet 9 and inches. FIG. 6B illustrates the corner insulation block 20 installed in the corner stud cavity 5 at an exemplary corner 1 of the 8 foot wall system 42.

[0043] As used herein, the term corner insulation block refers to a body of foam insulating material formed as a rectangular or square prism. The corner insulation block may have a width and thickness corresponding generally to the interior dimensions of a corner stud cavity and a length corresponding to the height of the wall system. Accordingly, the term corner insulation block encompasses elongated prism shapes of varying lengths, widths, and thicknesses that are suitable for insertion into wall cavities.

[0044] A method of installing a corner insulation block 20 into a corner stud cavity 5 of a wall system includes first receiving a corner insulation block 20 manufactured in a standard length, such as about 10 feet (L1). The corner insulation block 20 is provided with one or more cutting guides 28a, 28b positioned near one end 22 of the corner insulation block 20, each cutting guide 28a, 28b corresponding to a reduced length of the corner insulation block 20 appropriate for a particular wall height and thus height of the corner stud cavity 5. For example, as described above, the first cutting guide 28a is spaced about 1 foot from the first end 22, defining a length L2 of about 8 feet 9 and inches suitable for a 9 foot wall system, while the second cutting guide 28b is spaced about 2 feet from the first end 22, defining a length L3 of about 7 feet 9 and inches suitable for an 8 foot wall system.

[0045] The method further includes sizing the corner insulation block 20 to the corner stud cavity 5, and in particular sizing a length of the corner insulation block 20 to the corner stud cavity 5. This requires determining, such as through measuring, a length of the corner stud cavity 5 and comparing that length to the provided length of the corner insulation block 20. The length of the corner stud cavity 5 may be a measurement taken along the height of the wall system, such as between the bottom plate 29 and the ceiling 32 of the structure 2, for example. If the length of the corner insulation block 20 is greater than the length of the corner stud cavity 5, selecting a cutting guide 28a, 28b (or no cutting guide 28a, 28b) corresponding to the wall height and thus height of the corner stud cavity 5 and cutting the corner insulation block 20 along the selected cutting guide 28a, 28b to achieve the appropriate length of the corner insulation block 20 for installation in the corner stud cavity 5. Once sized, the corner insulation block 20 may be inserted into the corner stud cavity 5 of the wall system 26. The width W and thickness T of the corner insulation block 20 substantially match the interior dimensions of the corner stud cavity 5, thereby allowing the block 20 to occupy 90% or more of the space of the corner stud cavity 5 and provide thermal insulation at the wall corner 1.

[0046] Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as about, substantially, and approximately, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components and/or systems. For example, the approximating language may refer to being within a 10 percent margin.

[0047] From the above disclosure of the general principles of this invention and the preceding detailed description of at least one embodiment, those skilled in the art will readily comprehend the various modifications to which this invention is susceptible. Therefore, I desire to be limited only by the scope of the following claims and equivalents thereof.