An insulated exterior wall assembly combining insulating material and reflective surface insulation coupled with an air gap. A wall assembly according to this invention includes wall support studs defining insulation cavities between them, sheathing boards facing the building exterior, an insulating
An insulated exterior wall assembly combining insulating material and reflective surface insulation coupled with an air gap. A wall assembly according to this invention includes wall support studs defining insulation cavities between them, sheathing boards facing the building exterior, an insulating material such as cellular plastic material or fibrous insulation applied from the exterior sheathing partly through the depth of the insulation cavities, a foil-backed gypsum-containing wallboard applied to the interior facing portions of the studs, with an air gap between the foil backing of the wallboards and the surface of the foam along the depth of the studs. The wall assembly according to this invention provides comparable thermal resistance compared to a deep layer of insulating material.
대표청구항▼
1. A gypsum-containing board, the gypsum-containing board having a core comprising gypsum, a first face and a second face, a low-emittance surface material on the second face that is a metallic foil or film having perforations that are sized and shaped by contacting the metallic foil or film with pi
1. A gypsum-containing board, the gypsum-containing board having a core comprising gypsum, a first face and a second face, a low-emittance surface material on the second face that is a metallic foil or film having perforations that are sized and shaped by contacting the metallic foil or film with pins tapering to a point and spaced in a ¼ inch diamond pattern, the low-emittance surface material having an emittance of less than 0.25, the gypsum-containing board with low-emittance surface material having a water vapor permeance greater than 5 Perms. 2. The gypsum-containing board according to claim 1, wherein the low-emittance surface material is laminated to the second face of the board. 3. The gypsum-containing board according to claim 1, wherein the metallic foil or film is aluminum foil. 4. The gypsum-containing board according to claim 2, wherein the metallic foil or film is perforated before it is laminated to the second face of the board. 5. The gypsum-containing board according to claim 2, wherein the metallic foil or film is perforated after it is laminated to the second face of the board. 6. The gypsum-containing board according to claim 1, wherein the low-emittance surface material has an emittance of about 0.03 or less. 7. The gypsum-containing board according to claim 1 wherein the low-emittance surface material is adhered to a board facing, and the facing comprises glass fiber mat. 8. The gypsum-containing board according to claim 1 wherein the low-emittance surface material is perforated such that the water vapor permeance of the board is greater than 1 Perm. 9. The gypsum-containing board according to claim 1 wherein the low-emittance surface material is perforated such that the water vapor permeance of the board is greater than 5 Perms. 10. An insulated exterior wall system in a building comprising: a. two framing studs placed a uniform distance apart along an exterior portion of a building, each of the studs having a length, a width and a depth, a surface spanning the width of each stud facing outward of the building, a second surface spanning the width of each stud facing inward into the building;b. one or more sheathing boards fastened to the outward-facing surfaces of the studs so as to cover the area between the outward-facing surfaces of the studs, the sheathing boards having an outward face and an inward face;c. one or more wallboards fastened to the inward-facing surfaces of the framing studs so as to cover the area between the inward-facing surfaces of the studs, the wallboards having an outward face and an inward face;d. an insulation cavity having a depth equal to the depth of the studs defined by the studs, the sheathing boards, and the wallboards;e. a low-emittance surface material that is a metallic foil or film having perforations that are sized and shaped by contacting the metallic foil or film with pins tapering to a point and spaced in a ¼ inch diamond pattern and having an emittance of less than 0.25 applied to one of the outward-facing surface of the wallboards or the inward-facing surface of the sheathing boards, wherein the wallboard or the sheathing board to which the low-emittance surface material is applied is a board with a core comprising gypsum and wherein the wallboard with low-emittance surface material has a water vapor permeance greater than 1 Perm;f. a layer of insulating material applied to the other of the outward-facing surface of the gypsum-containing wallboards or the inward-facing surface of the sheathing boards, said layer filling the insulation cavity for a portion of the depth from the applied surface; andg. an air gap in the insulation cavity between the low-emittance surface material and the layer of insulating material. 11. An insulated exterior wall system according to claim 10, wherein the low-emittance surface material is laminated to the wallboards or sheathing boards. 12. An insulated exterior wall system according to claim 10, wherein the metallic foil or film is aluminum foil. 13. An insulated exterior wall system according to claim 11, wherein the metallic foil or film is perforated so that the gypsum-containing board laminated with the metallic foil or film surface has a water vapor permeance greater than 5 Perms. 14. An insulated exterior wall system according to claim 10, wherein the low-emittance surface material is applied to the outward surface of the wallboards. 15. An insulated exterior wall system according to claim 10, wherein the low-emittance surface material is applied to the inward surface of the sheathing boards. 16. An insulated exterior wall system according to claim 10, wherein the studs are 2×4 lumber, having an actual width of approximately 1.5 inches and a depth of approximately 3.5 inches. 17. An insulated exterior wall system according to claim 10, wherein the studs are placed approximately 16 inches apart from one another. 18. An insulated exterior wall system according to claim 10, wherein the insulating material is a cellular plastic material. 19. An insulated exterior wall system according to claim 10, wherein the insulating material is polyurethane or polyisocyanurate foam. 20. An insulated exterior wall system according to claim 10, wherein the insulating material is fibrous insulation. 21. An insulated exterior wall system according to claim 10, wherein the insulating material is applied to the cavity by spraying, or applied as a preformed sheet or batt. 22. An insulated exterior wall system according to claim 10, wherein the low-emittance surface material has an emittance of about 0.03 or less. 23. An insulated exterior wall system according to claim 10, wherein the air gap extends for 0.75 inch or more of the depth of the insulation cavity. 24. An insulated exterior wall system according to claim 10, wherein the insulation is applied to a depth of 1.5 to 2.5 inches. 25. A method for insulating an exterior wall cavity, the wall cavity comprising the space between two or more studs placed a uniform distance apart, the studs having surfaces facing outward of the building, and surfaces facing inward into the building, the method comprising: a. applying one or more boards to one of the outward surfaces of the studs or the inward surfaces of the studs to partially enclose the exterior wall cavity;b. applying an insulation material to the boards so as to partially fill the depth of the exterior wall cavity; andc. fastening one or more reflective gypsum-containing boards to the other of the outward surfaces of the studs or the inward surfaces of the studs, wherein the reflective gypsum-containing boards have at least one face with a low-emittance surface material that is a metallic foil or film having perforations that are sized and shaped by contacting the metallic foil or film with pins tapering to a point and spaced in a ¼ inch diamond pattern, the low-emittance surface material having an emittance of less than 0.25 and wherein the gypsum containing boards with low-emittance surface material has a water vapor permeance greater than 1 Perm, the low-emittance surface material faces into the exterior wall cavity, and an air gap is created between the low-emittance surface material and the layer of insulating material. 26. The gypsum-containing board according to claim 1, wherein the pins contact the metallic foil or film at a pressure of at least about 40 psi. 27. The gypsum-containing board according to claim 1, wherein the pins have a height of 0.25 inches and taper from about 0.078 inches in diameter to a point, and contact the metallic foil or film occurs at a pressure of about 50 psi.
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