VAPOR RETARDER SYSTEM

Abstract

A vapor retarder system comprises a vapor retarder and a sealant strip. The sealant strip is adhesively coupled to the vapor retarder to form a continuous vapor retarder.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. Provisional Patent Application No. 62/345,954, filed 6 Jun. 2016, the disclosure of which is now expressly incorporated herein by reference.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to vapor retarders and more specifically to vapor retarder systems fastened to interior walls of a structure.

BACKGROUND

In areas where building code requires a vapor retarder, loose fill insulative material (fiberglass, rockwool, cellulose and others) is installed behind netting or mesh that allows the air generated by the blowing machine that delivers the loose fill insulation to exhaust through the netting while the netting holds the insulation in place. After installing the loose fill insulation, the installer must install a vapor retarder over the netting to form a continuous vapor retarder on the wall. This multi-step process requires additional labor and additional material be used to install the vapor retarder.

SUMMARY

The present disclosure may comprise one or more of the following features and combinations thereof.

A method of insulating a wall may include providing a wall structure and providing a vapor retarder. The wall structure may include a first stud and a second stud each extending from a floor to a ceiling. Each stud may be spaced-apart from one another to form a gap therebetween. The vapor retarder may include a retarder strip and a vent strip.

In some embodiments, the method includes fastening the vapor retarder to each of the first and second studs to enclose the gap and form a cavity therein. The method may further include inserting insulative material into the cavity. In some embodiments, the method includes sealing the vent strip with a sealant strip.

In some embodiments, the sealant strip and the retarder strip cooperate to form a continuous vapor retarder system that retards vapor flow into the cavity from an external environment.

In some embodiments, the vent strip includes vent apertures and a web. The vent apertures are configured to allow air to pass freely between the cavity and the environment. The web extends between and interconnects the vent apertures.

In some embodiments, air flows out of the vent apertures into the external environment during the step of inserting insulative material.

In some embodiments, the step of inserting includes puncturing a portion of the web to form an insertion aperture configured to locate a nozzle therethrough and blowing insulative material through the nozzle into the cavity.

In some embodiments, the vapor retarder is fastened to each of the first stud and second stud with staples. In some embodiments, the insulative material is loose fill insulation.

In some embodiments, the vapor retarder has a first retarder strip, a second retarder strip and the vent strip extends between and interconnects the first retarder strip and the second retarder strip.

According to another aspect of the present disclosure, a vapor retarder system may include a vapor retarder and a sealant strip. The vapor retarder may be adapted to be fastened to an interior surface of a structure to form a cavity. The vapor retarder may include a vent strip and a retarder strip coextensive with the vent strip. The sealant strip may be adapted to overlie the vent strip. The sealant strip and the retarder strip may cooperate to form a continuous vapor retarder system that retards vapor flow into the cavity from an external environment.

In some embodiments, the vapor retarder is coupled to a vertical wall. In other embodiments, the vapor retarder is coupled to a horizontal surface. In some embodiments, the vapor retarder is coupled to a garage ceiling.

According to another aspect of the present disclosure a method of insulating a wall may comprise fastening a vapor retarder to each of a first and second stud of the wall to form a cavity therein, wherein the vapor retarder comprises a first vent strip and a first retarder strip; inserting insulative material into the cavity; and sealing the first vent strip with a sealant strip. In some embodiments, the sealant strip and the first retarder strip cooperate to form a continuous vapor retarder system that retards vapor flow into the cavity from an external environment.

In some embodiments, the first vent strip is formed to include a plurality of vent apertures configured to allow air to pass freely between the cavity and the external environment and a web extending between and interconnecting the plurality of vent apertures. In some embodiments, air flows out of the vent apertures into the external environment during the step of inserting insulative material.

In some embodiments, the step of inserting includes puncturing a portion of the web to form an insertion aperture configured to locate a nozzle therethrough.

In some embodiments, the method further comprises blowing insulative material through the nozzle into the cavity. In some embodiments, the vapor retarder is fastened to each of the first and second studs with staples. In some embodiments, the insulative material is loose fill insulation.

In some embodiments, the vapor retarder further comprises a second retarder strip and the first vent strip extends between and interconnects the first retarder strip and the second retarder strip.

In some embodiments, the vapor retarder further comprises a second vent strip located in spaced-apart relation to the first vent strip to locate the first retarder strip therebetween. In some embodiments, the step of inserting includes puncturing the first vent strip, the second vent strip, or a combination thereof.

In some embodiments, the sealant strip comprises a backing layer and an adhesive layer. In some embodiments, wherein the sealant strip locates a portion of the first vent strip between the backing layer and the cavity. In some embodiments, the adhesive layer comprises a pressure-sensitive adhesive.

According to another aspect of the present disclosure, a vapor retarder system may comprise a vapor retarder adapted to be fastened to an interior surface of a structure to form a cavity. In some embodiments, the vapor retarder includes a first vent strip and a first retarder strip coextensive with the first vent strip. In some embodiments, the vapor retarder comprises a sealant strip adapted to overlie to the first vent strip. In some embodiments, the sealant strip and the first retarder strip cooperate to form a continuous vapor retarder system that retards vapor flow into the cavity from an external environment.

In some embodiments, the first vent strip comprises a plurality of vent apertures. In some embodiments, the vent apertures are generally round. In some other embodiments, the vent apertures are slits.

In some embodiments, the first vent strip further comprises a web extending between and interconnecting the plurality of vent apertures.

In some embodiments, the vapor retarder further includes a second vent strip located in spaced-apart relation to the first vent strip to locate the first retarder strip therebetween.

According to another aspect of the present disclosure, an insulated wall may comprise the wall comprising a first stud and a second stud located in spaced-apart relation to the first stud. In some embodiments, the insulated wall may further comprise a vapor retarder fastened with the first stud and the second stud and to form a cavity therein, and the vapor retarder is formed to include a plurality of vent apertures. In some embodiments, the insulated wall comprises a sealant strip coupled to the vapor retarder to locate the plurality of vent apertures between the sealant strip and the cavity. In some embodiments, the vapor retarder and the sealant strip cooperate to retard vapor flow between the cavity and an external environment.

These and other features of the present disclosure will become more apparent from the following description of the illustrative embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an elevation view of a vapor retarder system in accordance with the present disclosure showing the vapor retarder system includes a vapor retarder fastened to a wall to enclose insulative material therein, and a sealant strip coupled to a portion of the vapor retarder;

FIG. 2 is a sectional view taken generally along line 2-2 of FIG. 1 showing from bottom to top the insulative material extending between a first stud and a second stud, a vent strip comprising vent apertures that extend through the vent strip and open into the insulative material, and the sealant strip comprising an adhesive layer and a backing layer coupled to the vent strip to overlie the vent apertures;

FIG. 3 is a detail view of a portion of the vapor retarder system of FIG. 1, showing the sealant strip overlying the vent strip with a portion of the sealant strip peeled back to show the underlying vent strip including an insertion aperture, the vent apertures, and a web extending between and interconnecting the vent apertures, and a portion of the vent strip peeled back to show the underlying insulative material and wall structure;

FIG. 4 is an elevation view of another embodiment of a vapor retarder system in accordance with the present disclosure, showing that the vapor retarder system includes a first vent strip, a second vent strip, and a first retarder strip extending between the first and second vent strips;

FIG. 5 is an elevation view of another embodiment of a vapor retarder system in accordance with the present disclosure, showing that the vapor retarder system includes a first vent strip and a second vent strip, and further showing that the vent apertures are generally slits;

FIG. 6 is a detail view of a portion of the vapor retarder system of FIG. 5, showing the sealant strip overlying the vent strip with a portion of the sealant strip peeled back to show the underlying vent strip having an insertion aperture, the slit-shaped vent apertures, and a web extending between and interconnecting the vent apertures, and a portion of the vent strip peeled back to show the underlying insulative material and wall structure; and

FIG. 7 is a diagrammatic view of an illustrative embodiment of a method of installing the vapor retarder system.

DETAILED DESCRIPTION OF THE DRAWINGS

For the purposes of promoting an understanding of the principles of the disclosure, reference will now be made to a number of illustrative embodiments illustrated in the drawings and specific language will be used to describe the same.

A vapor retarder system 10 can be mounted to a wall 18 to form an insulated wall 11, as shown in FIG. 1. The vapor retarder system 10 can provide an insulative value to the wall while also retarding the flow of vapor from an external environment. The vapor retarder system 10 includes a vapor retarder 14 adapted to be fastened to the wall 18. When fastened to the wall 18, the vapor retarder 14 is configured to vent excess pressure during a step of blowing an insulative material 12 into a cavity 28 formed between the vapor retarder 14 and the wall 18. A sealant strip 16 can then be applied to the vapor retarder 14 to prevent the flow of vapor between the cavity 28 and an external environment. A second embodiment of a vapor retarder system 210 is shown in FIG. 4. A third embodiment of a vapor retarder system is shown in FIGS. 5 and 6. A method 100 of installing a vapor retarder system 10 is shown in FIG. 7.

The vapor retarder system 10 includes the insulative material 12, the vapor retarder 14, sometimes called a ventable vapor retarder 14, and the sealant strip 16, as shown in FIGS. 1 and 3. The insulative material 12 provides an insulative value to the insulated wall 11. The ventable vapor retarder 14 fastens to the wall 18 to locate the insulative material 12 therein. The sealant strip 16 couples to a portion of the ventable vapor retarder 14. The sealant strip 16 cooperates with the ventable vapor retarder 14 to retard the flow of vapor through the vapor system 10.

The wall 18 includes a first stud 20 and a second stud 21 that each extend from a floor or sill plate 22 to a ceiling or top plate 24, as shown in FIG. 1. The first stud 20 and the second stud 21 cooperate to form a gap therebetween.

The ventable vapor retarder 14 couples to the wall 18 to enclose the gap and form a cavity 28, as shown in FIGS. 1-3. The ventable vapor retarder 14 includes a vent strip 30 and at least one retarder strip 32 as shown in FIG. 1. The vent strip 30 allows air to be released from the cavity 28 during an insulating operation. The retarder strip 32 retards the flow of vapor through a portion of the vapor retarder 14. In an embodiment, the ventable vapor retarder 14 has first retarder strip 32 and a second retarder strip 44 located in spaced-apart relation to the first retarder strip 32. In the illustrative embodiment, the vent strip 30 extends between and interconnects the first and second retarder strips 32, 44, as shown in FIGS. 1 and 3. Illustratively, the ventable vapor retarder 14 is fastened to the wall 18 with staples 33 into the first and second studs 20, 21. Illustratively, the vent strip spans the distance between the first and second studs 20, 21.

The sealant strip 16 adheres to the ventable vapor retarder 14 and includes an adhesive layer 34 and a backing layer 36, as shown in FIG. 2. The adhesive layer 34 extends between and interconnects the backing layer 36 and the ventable vapor retarder 14. The backing layer 36 is configured to retard the flow of vapor therethrough.

In an embodiment, the sealant strip 16 is a tape that adheres to the ventable vapor retarder 14. In another embodiment, the sealant strip 16 is a continuous piece of plastic that adheres to the ventable vapor retarder 14. In another embodiment, the sealant strip 16 is any type of material qualifying as a vapor retarder of 1 perm or less. The sealant strip 16 cooperates with the ventable vapor retarder 14 to form a continuous vapor block that prevents or minimizes the flow of vapor.

The vent strip 30 is configured to allow pressure venting during a blown insulation process. The vent strip 30 is formed to include the vent apertures 38 and a web 40, as shown in FIGS. 2 and 3. The vent apertures 38 are configured to allow air to pass freely between the cavity 28 and the environment. The web 40 extends between and interconnects the vent apertures 38 and provides at least a portion of a surface that couples to the sealant strip 16, as shown in FIG. 2. In an embodiment, the vent strip 30 is parallel to the floor or sill plate 22.

The vent strip 30 can have a range of widths that are illustratively generally measured in a direction that is perpendicular to the floor 22. The width of the vent strip 30 may be one of the following values: about 4 inches, about 6 inches, about 8 inches, about 10 inches, about 12 inches, about 15 inches, about 16 inches, about 20 inches, about 24 inches, about 28 inches, or about 30 inches wide. The vent strip 30 may be about 4 inches to about 30 inches, about 6 inches to about 30 inches, about 8 inches to about 30 inches, about 12 inches to about 30 inches about 12 inches to about 24 inches, or about 12 inches to about 18 inches wide. In an illustrative embodiment, the vent strip is about 6 inches wide. In another illustrative embodiment, the vent strip 30 is about 12 inches wide. In yet another illustrative embodiment, the vent strip 30 is about 18 inches wide.

In some embodiments, each aperture 38 of the vent apertures 38 is generally circular, as shown in FIGS. 1 and 3. Illustratively, each of the apertures 38 can be about 0.25 inches in diameter and be spaced about 3 inches apart. In another embodiment, each aperture is about 0.5 inches in diameter. While circular apertures 38 are illustratively described herein, any suitable shape or spacing of the plurality of apertures 38 that sufficiently allow escape of blown air may be used in the vent strip 30. In another embodiment, each aperture 38 of the plurality of apertures 38 has an irregular shape.

The apertures 38 are located in spaced-apart relation to one another, as shown in FIGS. 1-3. In a vertical direction, each aperture may be about 0.1 inches, about 0.25 inches, about 0.5 inches, about 0.75 inches, about 1 inch, about 1.25 inches, about 1.5 inches, about 1.75 inches, about 2 inches, about 2.5 inches, or about 3 inches away from a neighboring aperture 38. In some embodiments, each vent aperture can be about 0.1 inches to about 3 inches, about 0.5 inches to about 3 inches, about 0.5 inches to about 2.5 inches, about 0.5 inches to about 2 inches, about 0.75 inches to about 2 inches, or about 1 inch to about 3 inches away from a neighboring aperture 38.

The apertures 38 are located in spaced-apart relation to one another, as shown in FIGS. 1-3. In a horizontal direction, each aperture may be about 0.1 inches, about 0.25 inches, about 0.5 inches, about 0.75 inches, about 1 inch, about 1.25 inches, about 1.5 inches, about 1.75 inches, about 2 inches, about 2.5 inches, or about 3 inches away from a neighboring aperture 38. In some embodiments, each vent aperture can be about 0.1 inches to about 3 inches, about 0.5 inches to about 3 inches, about 0.5 inches to about 2.5 inches, about 0.5 inches to about 2 inches, about 0.75 inches to about 2 inches, or about 1 inch to about 3 inches away from a neighboring aperture 38.

The insulative material 12 is located within the cavity 28, as shown in FIGS. 1-3. In an embodiment, the insulative material 12 is loose fill insulation such as fiberglass, rockwool, cellulose or any other suitable loose fill insulation. The insulative material 12 cooperates with the structure of the wall 18 to provide an insulative value. In some embodiments, the vapor retarder system 10 provides an insulative value of about R-5 to about R-49, about R-5 to about R-35, about R-5 to about R-15, or about R-15 to about R-35.

The vapor retarder system 10 retards the flow of vapor between the cavity 28 and an external environment. In some embodiments, the external environment is an interior room of a structure and the vapor retarder system 10 is located between the interior room of the structure and an exterior of the structure. In some embodiments, the vapor retarder system 10 is located between the interior room of the structure and the first and second studs 20, 21, as shown in FIG. 1. In some embodiments, the external environment is outside of the structure and the vapor retarder system is located between the exterior of the structure and the first and second studs 20, 21. In some embodiments, the vapor retarder system 10 retards the flow of vapor from the cavity 28 into the interior room of the structure. The vapor retarder system 10 can provide a perm rating of less than about 3, less than about 2, less than about 1, less than about 0.8, less than about 0.5, or less than about 0.3.

In some embodiments, the ventable vapor retarder 14 comprises a polyethylene film. The thickness of the ventable vapor retarder 14 may be one of the following values: about 1 mil to about 10 mils, about 1 mil to about 8 mils, about 2 mils to about 8 mils, about 3 mils to about 8 mils, about 4 mils to about 8 mils, and about 4 mils to about 7 mils. The thickness of the ventable vapor retarder 14 may be one of the following values, about 1 mil, about 2 mils, about 3 mils, about 4 mils, about 5 mils, about 6 mils, about 7 mils, about 8 mils, about 9 mils, and about 10 mils. In an embodiment, the ventable vapor retarder 14 is about 6 mils thick.

In another embodiment in accordance with the present disclosure, the ventable vapor retarder 14 can be installed on a horizontal surface. Illustrative horizontal surfaces include garage ceilings and floors.

During the preparation of the insulated wall 11, a technician may insert a fill nozzle into the first vent strip 30 and form an insertion aperture 42, as shown in FIG. 1. The technician may then add insulative material 12 to the cavity 28. In some embodiments, a technician may insert a fill nozzle into the first retarder strip 32. If a technician inserts a fill nozzle into the first retarder strip 32, a patch may be applied to the vapor retarder 14 to seal the aperture formed in the first retarder strip 32.

Another illustrative vapor retarder system 210 adapted for use on a wall is shown in FIG. 4. The vapor retarder system 210 is substantially similar to the vapor retarder system 10 shown in FIGS. 1-3 and described herein. Accordingly, similar reference numbers in the 200 series indicate features that are common between the vapor retarder system 10 and the vapor retarder system 210. The description of the vapor retarder system 10 is hereby incorporated by reference to apply to the vapor retarder system 210, except in instances when it conflicts with the specific description and drawings of the vapor retarder system 210.

The vapor retarder system 210 includes the insulative material 212, the vapor retarder 214, sometimes called a ventable vapor retarder 214, and the sealant strip 216, as shown in FIG. 4. Illustratively, the first sealant strip 216 couples to a portion of the ventable vapor retarder 214 and cooperates with the ventable vapor retarder 214 to retard the flow of vapor through the vapor retarder system 210.

The vapor retarder 214 comprises a first vent strip 230, a second vent strip 231, and a first retarder strip 232 as shown in FIG. 4. The first vent strip 230 is located in spaced-apart relation to the second vent strip 231. Illustratively, the first vent strip 230 is located between the first retarder strip 232 and the top plate 224. The second vent strip 231 is located between the first vent strip 230 and the sill plate 222. The first retarder strip 232 extends between and interconnects the first vent strip 230 and the second vent strip 231.

In some embodiments, the vapor retarder 214 comprises a second retarder strip 244 and a third retarder strip 245 located in spaced-apart relation to the second retarder strip 244, as shown in FIG. 4. The second retarder strip 244 is located between the first vent strip 230 and the top plate 224. The third retarder strip 245 is located between the second vent strip 231 and the sill plate 222.

The insulative material 212 provides an insulative value to the insulated wall 211. The ventable vapor retarder 214 fastens to the wall 218 to locate the insulative material 212 therein. The insulative material 212 is located within the cavity 228, as shown in FIG. 4 In an embodiment, the insulative material 212 is loose fill insulation such as fiberglass, rockwool, cellulose or any other suitable loose fill insulation. The insulative material 212 cooperates with the structure of the wall 218 to provide an insulative value. In some embodiments, the vapor retarder system 210 provides an insulative value of about R-5 to about R-49, about R-5 to about R-35, about R-5 to about R-15, or about R-15 to about R-35.

In some embodiments, the vapor retarder system 210 comprises a first sealant strip 216 and a second sealant strip 217, as shown in FIG. 4. Each of the first and second sealant strips 216, 217 adhere to the vapor retarder 214. Each of the first and second sealant strips 216, 217 include an adhesive layer 234 and a backing layer 236. The adhesive layer 234 extends between and interconnects the backing layer 236 and the ventable vapor retarder 214. In an embodiment, the first and second sealant strips 216, 217 are each a continuous piece of plastic adhered to the ventable vapor retarder 214. In another embodiment, the sealant strips 216, 217 comprise any type of material qualifying as a vapor retarder of 1 perm or less. The sealant strips 216, 217 cooperate with the ventable vapor retarder 214 to form a continuous vapor retarder.

Illustratively, the first sealant strip 216 is configured to locate the first vent strip 230 between the backing layer 236 of the first sealant strip and the cavity 228, as shown in FIG. 4. The second sealant strip 217 is configured to locate the second vent strip 231 between the backing layer 236 of the second sealant strip 217 and the cavity 228. Illustratively, the first and second sealant strips 216 cooperate with the first, second, and third retarder strips 232, 244, 245 to form a continuous barrier against vapor transmission.

During the preparation of the insulated wall 211, a technician may insert a fill nozzle into the first vent strip 230, the second vent strip 231, or both the first and second vent strips 230, 231 and form an insertion aperture 242. The technician may then add insulative material 212 to the cavity 228.

In some embodiments, a technician may insert a fill nozzle into the first retarder strip 232. If a technician inserts a fill nozzle into the first retarder strip 232, a patch may be applied to the vapor retarder 214 to seal the aperture formed in the first retarder strip 232.

Another illustrative vapor retarder system 310 adapted for use on a wall is shown in FIGS. 5-6. The vapor retarder system 310 is substantially similar to the vapor retarder system 10 shown in FIGS. 1-3 and described herein. Accordingly, similar reference numbers in the 300 series indicate features that are common between the vapor retarder system 10 and the vapor retarder system 310. The description of the vapor retarder system 10 is hereby incorporated by reference to apply to the vapor retarder system 310, except in instances when it conflicts with the specific description and drawings of the vapor retarder system 310.

The vapor retarder system 310 includes the insulative material 312, the vapor retarder 314, sometimes called a ventable vapor retarder 314, and the first sealant strip 316, as shown in FIGS. 5-6. Illustratively, the first sealant strip 316 couples to a portion of the ventable vapor retarder 314 and cooperates with the ventable vapor retarder 314 to retard the flow of vapor through the vapor retarder system 310.

The vapor retarder 314 comprises a first vent strip 330, a second vent strip 331, and a first retarder strip 332 as shown in FIG. 5. The first vent strip 330 is located in spaced-apart relation to the second vent strip 331. Illustratively, the first vent strip 330 is located between the second vent strip 331 and the top plate 324. The second vent strip 331 is located between the first vent strip 330 and the sill plate 322. The first retarder strip 332 extends between and interconnects the first vent strip 330 and the second vent strip 331.

The insulative material 312 provides an insulative value to the insulated wall 211. The ventable vapor retarder 314 fastens to the wall 318 to locate the insulative material 312 therein. The insulative material 312 is located within the cavity 328, as shown in FIG. 5 In an embodiment, the insulative material 312 is loose fill insulation such as fiberglass, rockwool, cellulose or any other suitable loose fill insulation. The insulative material 312 cooperates with the structure of the wall 318 to provide an insulative value. In some embodiments, the vapor retarder system 310 provides an insulative value of about R-5 to about R-49, about R-5 to about R-35, about R-5 to about R-15, or about R-15 to about R-35.

In some embodiments, the vapor retarder 314 comprises a second retarder strip 344 and a third retarder strip 345 located in spaced-apart relation to the second retarder strip 344, as shown in FIG. 5. The second retarder strip 344 is located between the first vent strip 330 and the top plate 324. The third retarder strip 345 is located between the second vent strip 331 and the sill plate 322. The insulative material 312 provides an insulative value to the insulated wall 311. The ventable vapor retarder 314 fastens to the wall 318 to locate the insulative material 312 therein. A sealant strip 316 couples to a portion of the ventable vapor retarder 314 and cooperates with the vapor retarder 314 to retard the flow of vapor.

In some embodiments, the vapor retarder system 310 comprises a first sealant strip 316 and a second sealant strip 317, as shown in FIG. 5. Each of the first and second sealant strips 316, 317 adhere to the vapor retarder 314. Each of the first and second sealant strips 316, 317 include an adhesive layer 334 and a backing layer 336. The adhesive layer 334 extends between and interconnects the backing layer 336 and the ventable vapor retarder 314. In an embodiment, the first and second sealant strips 316, 317 are each a continuous piece of plastic adhered to the ventable vapor retarder 314. In another embodiment, the first and second sealant strips 316, 317 comprise any type of material qualifying as a vapor retarder of 1 perm or less. The first and second sealant strips 316, 317 cooperate with the ventable vapor retarder 314 to form a continuous vapor retarder.

Illustratively, the first sealant strip 316 is configured to locate the first vent strip 330 between the backing layer 336 of the first sealant strip and the cavity 328, as shown in FIGS. 5 and 6. The second sealant strip 317 is configured to locate the second vent strip 331 between the backing layer 336 of the second sealant strip 317 and the cavity 328. Illustratively, the first and second sealant strips 316, 317 cooperate with the first, second, and third retarder strips 332, 344, 345 to form a continuous barrier against vapor transmission.

In an embodiment, each aperture of the vent apertures 338 is a slit, as shown in FIGS. 5 and 6. The apertures 338 may be generally parallel to the sill plate 322, generally perpendicular to the sill plate 322, generally diagonal to the sill plate 322, a mixture thereof, or oriented in a random direction relative to the sill plate 322. Illustratively, each of the apertures can be about 0.25 inches, about 0.5 inches, about 0.75 inches, about 1 inch, about 1.25 inches, about 1.5 inches, about 1.75 inches, about 2 inches, about 2.5 inches, or about 3 inches long. In some embodiments, each vent aperture can be about 0.25 inches to about 3 inches, about 0.5 inches to about 3 inches, about 0.5 inches to about 2.5 inches, about 0.5 inches to about 2 inches, about 0.75 inches to about 2 inches, or about 1 inch to about 3 inches long.

The apertures 338 are located in spaced-apart relation vertically to one another, as shown in FIG. 5. In a vertical direction, each aperture may be about 0.1 inches, about 0.25 inches, about 0.5 inches, about 0.75 inches, about 1 inch, about 1.25 inches, about 1.5 inches, about 1.75 inches, about 2 inches, about 2.5 inches, or about 3 inches away from a neighboring aperture 338. In some embodiments, each vent aperture can be about 0.1 inches to about 3 inches, about 0.5 inches to about 3 inches, about 0.5 inches to about 2.5 inches, about 0.5 inches to about 2 inches, about 0.75 inches to about 2 inches, or about 1 inch to about 3 inches away from a neighboring aperture 338.

The apertures 338 are located in spaced-apart relation horizontally to one another, as shown in FIG. 5. In a horizontal direction, each aperture may be about 0.1 inches, about 0.25 inches, about 0.5 inches, about 0.75 inches, about 1 inch, about 1.25 inches, about 1.5 inches, about 1.75 inches, about 2 inches, about 2.5 inches, or about 3 inches away from a neighboring aperture 338. In some embodiments, each vent aperture can be about 0.1 inches to about 3 inches, about 0.5 inches to about 3 inches, about 0.5 inches to about 2.5 inches, about 0.5 inches to about 2 inches, about 0.75 inches to about 2 inches, or about 1 inch to about 3 inches away from a neighboring aperture 338.

During the preparation of the insulated wall 311, a technician may insert a fill nozzle into the first vent strip 330, the second vent strip 331, or both the first and second vent strips 330, 331 and form an insertion aperture 342. The technician may then add insulative material 312 to the cavity 328.

In some embodiments, a technician may insert a fill nozzle into the first retarder strip 332. If a technician inserts a fill nozzle into the first, second, or third retarder strips 332, 344, 345 a patch may be applied to the vapor retarder 314 to seal the aperture formed in the first retarder strip 332.

A method 100 of insulating a wall 18 is shown diagrammatically in FIG. 7. In an embodiment, the method 100 includes providing 110 the wall 18. In some embodiments, the method 100 further includes providing 120 the ventable vapor retarder 14 comprising the vent strip 30 and at least one retarder strip 32, as shown in FIGS. 1-3. While some illustrative steps for method 100 are described for vapor retarder system 10, the method 100 applies with equal weight to vapor retarder systems 210, 310.

The method 100 further includes fastening 130 the ventable vapor retarder 14 to the wall 18 to enclose the gap between the first and second studs 20, 21 to form the cavity 28 therein as shown in FIG. 3. Illustratively, the ventable vapor retarder 14 is stapled to each of the first stud 20 and the second stud 21 with staples 33 to retain the ventable vapor retarder 14 on the wall throughout the method 100.

The method 100 further includes inserting 140 a fill nozzle into the vent strip 30 to form an insertion aperture 42 as shown in FIGS. 1 and 3. In some embodiments, the fill nozzle is inserted into the retarder strip 32.

The method further includes inserting 150 insulative material through the fill nozzle into the cavity 28. During the inserting 150 step, insulative material 12 is blown into the cavity 28 causing a pressure increase in the cavity 28. The excess pressure in the cavity 28 is able to escape the cavity 28 and pass into the environment through the vent apertures 38 of the vent strip 30. The method further comprises removing 160 the fill nozzle from the filled cavity 28.

The length of time for the step of inserting 150 the insulative material 12 may be dependent on the size of the cavity 28, the feed ratio of the air pressure and insulative material 12, and the duration of the step of inserting 150. Illustratively, the length of time for the step of inserting 150 may also dependent on the desired level of R-value for the insulated wall 11. In some embodiments, the step of inserting is performed for about 10 seconds, about 15 seconds, about 30 seconds, about 35 seconds, about 40 seconds, about 45 seconds, about 1 min, about 1.5 minutes, about 2 minutes, about 3 minutes, about 4 minutes, about 5 minutes, about 7 minutes, about 10 minutes or about 20 minutes. In some embodiments, the step of inserting is performed for about 10 seconds to about 20 minutes, about 30 seconds to about 10 minutes, about 30 seconds to about 5 minutes, or about 1 minute to about 5 minutes.

In some embodiments, the insulative material 12 is inserted into the cavity 28 at about 1 lb/30 seconds, about 1.5 lbs/30 seconds, about 2 lbs/30 seconds, about 2.5 lbs/30 seconds, about 3 lbs/30 seconds, about 3.5 lbs/30 seconds, about 4 lbs/30 seconds, about 4.5 lbs/30 seconds, about 5 lbs/30 seconds, about 5.5 lbs/30 seconds, about 6 lbs/30 seconds, about 6.5 lbs/30 seconds, about 7 lbs/30 seconds, about 8 lbs/30 seconds, about 9 lbs/30 seconds, or about 10 lbs/30 seconds. In some embodiments, the insulative material 12 is inserted into the cavity 28 at a rate of about 1 lb/30 seconds to about 10 lbs/30 seconds, about 1 lb/30 seconds to about 8 lbs/30 seconds, about 2 lbs/30 seconds to about 8 lbs/30 seconds, about 2 lbs/30 seconds to about 7 lbs/30 seconds, or about 3 lbs/30 seconds to about 7 lbs/30 seconds.

In some embodiments, the method 100 further comprises inserting 140 the fill nozzle into a second vent strip 231. In some embodiments, the method 100 comprises inserting the fill nozzle into a first vent strip 230 before inserting the fill nozzle into the second vent strip 231. In some embodiments, the method 100 comprises inserting the fill nozzle into the second vent strip 231 before inserting the fill nozzle into the first vent strip 230. In some embodiments, the second vent strip 231 is located between the first vent strip 230 and the sill plate 222. In some embodiments, the first vent strip 230 is located between the second vent strip 231 and the top plate 224.

The method further comprises sealing 170 the vent strip 30 with the sealant strip 16. The sealing 170 step locates the vent apertures 38 and the insertion aperture 42 between the sealant strip 16 and the insulative material 12 to retard vapor flow therethrough. Illustratively, the sealing 170 step forms the continuous vapor retarder. In an embodiment, the sealing step 170 includes applying an adhesive layer 34 to the ventable vapor retarder 14 and applying the backing layer 36 to the ventable vapor retarder 14. In some embodiments, the sealant strip 16 comprises a pressure sensitive adhesive and the step of sealing 170 includes applying the pressure-sensitive adhesive backed sealant strip 16 to the vapor retarder 14.

Loose fill insulation (fiberglass, rockwool, cellulose and others (e.g. insulative material 12) has long been installed behind netting or mesh that allows the air generated by the blowing machine that delivers the loose fill insulation to exhaust through the netting and hold the insulation in place behind the netting. Unfortunately, in climate zones where the building code requires a vapor retarder (e.g. vapor retarder system 10) be installed, the applicator must then install a vapor retarder over the netting. This process requires additional labor and additional material are used to install the vapor retarder. In general, it is a very inefficient method of installing the loose fill insulation (e.g. insulative material 12) when a vapor retarder is required.

After the cavities (e.g. cavity 28) have been filled with insulation (e.g. insulative material 12), the installers quickly seal the vented channel (e.g. vent strip 30) using a pressure sensitive tape (e.g. sealant strip 16), small sheet of poly adhered by spray adhesive, or any number of different types of material that has a minimum of 1 permanence rating.

The Integrated Vapor Retarder/Netting System (e.g. the ventable vapor retarder 14 and the sealant strip 16) may be more efficient and cost effective for the contractor, builder, and homeowner because it eliminates the additional cost of the vapor retarder material and additional labor to install the vapor retarder.

While the disclosure has been illustrated and described in detail in the foregoing drawings and description, the same is to be considered as exemplary and not restrictive in character, it being understood that only illustrative embodiments thereof have been shown and described and that all changes and modifications that come within the spirit of the disclosure are desired to be protected.

Claims

1. A method of insulating a wall comprising

fastening a vapor retarder to each of a first and second stud of the wall to form a cavity therein, wherein the vapor retarder comprises a first vent strip and a first retarder strip;

inserting insulative material into the cavity; and

sealing the first vent strip with a sealant strip,

wherein the sealant strip and the first retarder strip cooperate to form a continuous vapor retarder system that retards vapor flow into the cavity from an external environment.

2. The method of claim 1, wherein the first vent strip is formed to include a plurality of vent apertures configured to allow air to pass freely between the cavity and the external environment and a web extending between and interconnecting the plurality of vent apertures.

3. The method of claim 2, wherein air flows out of the vent apertures into the external environment during the step of inserting insulative material.

4. The method of claim 3, wherein the step of inserting includes puncturing a portion of the web to form an insertion aperture configured to locate a nozzle therethrough.

5. The method of claim 4, wherein the method further comprises blowing insulative material through the nozzle into the cavity.

6. The method of claim 1, wherein the vapor retarder is fastened to each of the first and second studs with staples.

7. The method of claim 1, wherein the insulative material is loose fill insulation.

8. The method of claim 1, wherein the vapor retarder further comprises a second retarder strip and the first vent strip extends between and interconnects the first retarder strip and the second retarder strip.

9. The method of claim 1, wherein the vapor retarder further comprises a second vent strip located in spaced-apart relation to the first vent strip to locate the first retarder strip therebetween.

10. The method of claim 9, wherein the step of inserting includes puncturing the first vent strip, the second vent strip, or a combination thereof.

11. The method of claim 1, wherein the sealant strip comprises a backing layer and an adhesive layer.

12. The method of claim 11, wherein the sealant strip locates a portion of the first vent strip between the backing layer and the cavity.

13. The method of claim 11, wherein the adhesive layer comprises a pressure-sensitive adhesive.

14. A vapor retarder system comprising

a vapor retarder adapted to be fastened to an interior surface of a structure to form a cavity, the vapor retarder including a first vent strip and a first retarder strip coextensive with the first vent strip; and

a sealant strip adapted to overlie to the first vent strip,

wherein the sealant strip and the first retarder strip cooperate to form a continuous vapor retarder system that retards vapor flow into the cavity from an external environment.

15. The vapor retarder system of claim 14, wherein the first vent strip comprises a plurality of vent apertures.

16. The vapor retarder system of claim 15, wherein the vent apertures are generally round.

17. The vapor retarder system of claim 15, wherein the vent apertures are slits.

18. The vapor retarder system of claim 15, wherein the first vent strip further comprises a web extending between and interconnecting the plurality of vent apertures.

19. The vapor retarder system of claim 14, wherein the vapor retarder further includes a second vent strip located in spaced-apart relation to the first vent strip to locate the first retarder strip therebetween.

20. An insulated wall comprising,

the wall comprising a first stud and a second stud located in spaced-apart relation to the first stud;

a vapor retarder fastened with the first stud and the second stud and to form a cavity therein, and the vapor retarder is formed to include a plurality of vent apertures; and

a sealant strip coupled to the vapor retarder to locate the plurality of vent apertures between the sealant strip and the cavity,

wherein the vapor retarder and the sealant strip cooperate to retard vapor flow between the cavity and an external environment.