Patent Publication Number: US-10773882-B2

Title: Shipping container insulation panel and installation method

Description:
BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present invention is directed to an insulation panel and insulating system, and in particular to an insulation panel and system configured for use in shipping containers. 
     Description of the Prior Art 
     Wall systems that require finishing and/or insulation are well known and take on numerous configurations such as masonry, concrete modular units, poured concrete walls, wood frameworks and other common structural systems that generally provide satisfactory installation and support. Often, walls require insulation and may also require finishing over the insulation. Moreover, a vapor barrier should often be established to prevent or minimize mold and moisture damage and resist rusting or other corrosion. Moreover, such systems should avoid high thermal conductivity and resist rusting or other corrosion. 
     Various types of insulation systems have been developed and are widely used including fiberglass insulation. However, fiberglass insulation is susceptible to water damage and mold if moisture is present. In addition, the thickness required for adequate insulation may decrease the overall size of the space due to the added depth of the fiberglass layer. Fiberglass insulation is also difficult to handle and requires special gloves and a respirator. Many types of foam insulation have also been developed and utilized for many applications. However, such foam types of insulation are often open foam so that the material allows moisture to pass through and may retain some moisture. Common stud and foam insulation systems also suffer from difficult installation as may be required for wiring, switches, tubing and other components along with the insulation. 
     To overcome such problems, systems have been developed that provide an insulation layer using panels that align and attach with one another and mount to the wall. Such a panel type system is shown in U.S. Pat. No. 8,635,824 entitled INSULATION PANEL SYSTEM and issued to Scherrer. Such systems were sold under the commercial name INSOFAST and have proven to be very successful in providing superior insulation systems provides multiple advantages over prior art systems. The INSOFAST panel systems are widely adapted to many types of applications and able to be used for radon abatement under adsorptive claddings, under exterior insulation finish systems (EIFS), for retrofitting drain and dry insulation for exterior existing structures, for retrofit of drain and dry insulation for interior of existing structures. The system has been used in existing flooring, against foundation walls, above grade concrete or frame construction on either the interior or exterior and can be matched up to existing frame walls for extra insulation. The panels can be used as an insulation board when mounted on the exterior and can be used on top of existing floors or plaster walls, even if damaged, or on ceilings. The system might may also be used to add additional insulation to insulated concrete forms and can be used in multiple layers and used in precast applications and can snap in for chases to keep the chase ways open. This system forms a weather resistant barrier that does not require tape or adhesives and has self-sealing attachment points with the internal studs making installation simple and reliable. 
     Although the INSOFAST system of U.S. Pat. No. 8,635,824 has been successful for a wide range of uses, particular applications require a different approach. It can be appreciated that large shipping containers may have cargos or applications that require insulation. Moreover, such shipping containers have become popular for use as tiny homes. Their strength and standard sizes of shipping containers also make them suitable for modular construction with multiple shipping containers joined to form a larger structure. Use of the shipping containers for building construction also typically requires insulation. Standard shipping containers are typically made of steel and have a corrugated type wall structure. Such corrugated walls provide alternating spaced apart recesses and protrusions that reduce the effectiveness of planar insulation systems due to the gaps. Moreover, the corrugated type walls of shipping containers provide for more difficult installation due to the spaced apart recesses of the corrugations. To address such installation challenges, planar systems such as the INSOFAST insulation system have been supplemented with strips of insulation material cut and trimmed to fill in the spaces formed by the corrugated wall and therefore eliminate the gaps. Although this approach provides satisfactory insulation performance, installation can be challenging and labor intensive as strips must be cut and installed along with the planar panels to eliminate the gaps. 
     It can be appreciated that a new and improved system is needed that provides for superior insulation of corrugated walls such as are present with shipping containers. Such a system should fill the gaps formed by a corrugated wall structure. Moreover, such a system should provide for obtaining a planar outer exposed surface for easy mounting of additional layers and/or finishing. Such a system should also achieve water, thermal and vapor control layers or barriers and should provide for easily forming chases and channels for wiring, plumbing and other structure. Such a system should be easy to install and provide alignment between adjacent panels laterally and vertically. The present invention addresses these as well as other problems associated with insulation of corrugated walls. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a wall insulating system and in particular to a wall insulation and finishing system suitable for use with standard shipping containers having corrugated walls. The present invention utilizes foam insulating panels that are connected to form an insulation layer with a planar outer face. The panels include mounting stud type elements molded into the panels. 
     According to the present invention, standard shipping containers provide alternating spaced apart recesses and protrusions that are difficult to effectively insulate due to the gaps. Moreover, the corrugated type walls of shipping containers increase installation difficulty due to the spaced apart recesses of the corrugations. Closed cell foam insulation panels of the present invention have an inner mounting face that is complementary to the corrugated surface of shipping container walls. The panels form an exposed planar surface that may be painted, wallpapered, paneled or finished using other well-known techniques. The panels have molded in mounting elements that are spaced apart at uniform on center spacing generally corresponding to spacing for standard wood studs and allow for easily fastening with glue and conventional hardware to the shipping container wall. The mounting elements also provide for attachment of drywall, wood paneling and other inner finishing type layers to the insulating panel layer. 
     The panels are generally made of water impervious foam material so that the panels are lightweight and easily transported. In typical embodiments, the panels are 24 inches×approximately 44 inches or 16 inches by approximately 44 inches, allowing for easily handling the panels at jobsites. The panels have a tongue and groove configuration along the edges for connecting to adjacent panels both vertically and horizontally to create a continuous insulating layer for an entire wall. The panels include alignment tabs and complementary notches along the top and bottom edges to ensure a proper engagement and placement. 
     The panels also include channels, passages and/or chases for routing wiring, tubing or other elements. A small strip is formed along the edges so that when panels are connected in an edge to edge relationship, a channel or chase is formed continuing horizontally along adjacent panels between the ends of the ridges of adjacent panels. With this configuration, wiring and other elements may be routed both horizontally and vertically along the width and height of a wall without having to modify the panels. The edges of the panels also have drainage channels so that water and moisture are directed back toward each face of the panel keeping water from migrating through the panel in either direction. The panels also include cutting channels so that clean, straight cuts may be simply and quickly made so that the panels have clean straight edges. 
     The mounting elements are molded into the panels in an embedded configuration in one embodiment. The mounting elements are generally elongate members with a somewhat “H” shaped cross-sectional profile. The first portion extends perpendicularly outward from its center section, which abuts a series of center connecting ribs. The second portion extends from an opposite end of the connecting ribs in a substantially perpendicular configuration with a very slight obtuse “V” shaped profile. The first portion extends to a first face of the panel or just below the first face and includes a channel or channels to receive and recess screw heads used to attach the panels. The second portion also extends to a second face of the panel and may include glue channels and also provides for receiving adhesive type materials. The mounting elements are preferably molded of lightweight plastic material that is impervious to rusting and other corrosion or deterioration and that can provide a foundation for attaching mounting hardware and also provide support for the panel. The mounting elements are non-conductive and do not produce any galvanic corrosion such as other steel framing that is connected to a steel shipping container. The mounting elements fasten in such a manner as to not puncture the shipping container walls that may initiate a future leak. The mounting elements are thermally non-conductive and provide a thermal break from the steel container wall to the interior finishes, unlike steel Z-furring that will lose as much as 50% or the R-value through thermal bridging. 
     To mount to corrugated walls, such as side walls of a shipping container, the inner mounting face of each panel has a corrugated inner facing surface that is complementary to the corrugated surface, such as the side walls of shipping container. The corrugated mounting surface includes vertically extending protruding portions alternating with vertically extending recesses. The protruding portions include a planar outer face and tapering connection surfaces that form a transition from the planar face of the inner recess to the planar face of the protruding portion. The inner recessed surface and the planar face of the protruding portions are generally parallel to one another and to the exposed surface on the opposite side of each panel. The protruding portions and the recesses extend generally vertically and configured to align with the complementary portions of the corrugated walls of the shipping container. The configuration of the insulation panels provides a tight fit against the corrugated walls without leaving gaps. 
     The insulation system is easily installed. The panels are installed by gluing or conventional mechanical fasteners to corrugated walls. Panels are placed starting at a lowermost tier and usually in one corner and working horizontally across the width of a wall. The tongues and grooves form connections between adjacent panels so that a continuous water impervious layer is achieved. The panels of each level are typically offset relative to adjacent panels above and below, but are correctly positioned and spaced by the alignment tabs and notches. Moreover, the protruding portions and recesses of the panels are complementary and mate with the corrugated wall and are correctly positioned through the alignment tabs and notches of the panels. Construction of the insulating layer continues in a level by level configuration until reaching the top of the wall. The panels may be trimmed to remove the tongue and grooves from the edges abutting the floor, ceiling and corners for continuous total coverage of the structural wall. After the glue dries, further hardware may be used for mounting to the load bearing wall. Drywall, paneling or other layers may then be attached using conventional hardware to the mounting elements. It can be appreciated that no special skills or special tools are needed for installation. Electrical boxes and other devices may be installed by simply cutting out the portions of a panel and connecting to the wiring or other elements extending through the channels formed by the panels. 
     The present invention is lightweight, durable, easy to install, long lasting, has improved insulation attributes, is inexpensive, can be used for retrofit applications and minimizes common drawbacks of traditional construction such as mold, water damage and other problems associated with the prior art. The system uses panels that fasten to a structural wall and easy to cut with a conventional knife for individually sizing the panels or cutting additional chases or channels as the panels do not have a metal layer that is thermally conductive or other material that is difficult to cut. The panels have built in utility chases, drainage channels and inter-panel alignment without using special tracks or plates. It can be appreciated that some local ordinances may prohibit the exterior of a shipping container used in constructing a building from being visible. The integrated mounting elements of the insulation system of the present invention provide for easy attachment of conventional exterior claddings. 
     These features of novelty and various other advantages that characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and the objects obtained by its use, reference should be made to the drawings that form a further part hereof, and to the accompanying descriptive matter, in which there is illustrated and described a preferred embodiment of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Referring now to the drawings, wherein like reference letters and numerals indicate corresponding structure throughout the several views: 
         FIG. 1  is a perspective view of a shipping container with portions removed for clarity and with a portion of one wall covered with an insulation system according to the principles of the present invention; 
         FIG. 2  is a front perspective view of an insulation panel according to the principles of the present invention; 
         FIG. 3  is a rear elevational view of the insulation panel shown in  FIG. 2 ; 
         FIG. 4  is a front elevational view of the insulation panel shown in  FIG. 2 ; 
         FIG. 5  is a rear elevational view of the insulation panel shown in  FIG. 2 ; 
         FIG. 6  is a right side elevational view of the insulation panel shown in  FIG. 2 ; 
         FIG. 7  is a top plan view of the insulation panel shown in  FIG. 2 ; 
         FIG. 8  is a bottom plan view of the insulation panel shown in  FIG. 2 ; 
         FIG. 9  is a perspective view of mounting element embedded in the panel shown in  FIG. 2 ; 
         FIG. 10  is a side elevational view of the mounting element shown in  FIG. 9 ; 
         FIG. 11  is an end elevational view of the mounting element shown in  FIG. 9 ; 
         FIG. 12  is a sectional view taken through a wall of the shipping container shown in  FIG. 1  with insulation panels installed; 
         FIG. 13  is an elevational view of an inner wall of the shipping container shown in  FIG. 1  with insulation panels installed on a portion of the wall; 
         FIG. 14  is a perspective view of a shipping container with portions removed for clarity and with a portion of one outer wall covered with an insulation system according to the principles of the present invention; 
         FIG. 15  is an elevational view of an outer wall of the shipping container shown in  FIG. 1  with insulation panels installed on a portion of the outer wall; 
         FIG. 16  is a sectional view taken through a wall of the shipping container shown in  FIG. 1  with insulation panels installed on an exterior face of the wall and the interior face of the wall; 
         FIG. 17  is a perspective view of a shipping container with portions removed for clarity and with a portion of one outer wall and a portion of the inner wall covered with an insulation system according to the principles of the present invention; 
         FIG. 18  is a sectional view taken through a wall of the shipping container shown in  FIG. 1  with insulation panels installed on an interior face and an exterior face of the wall; 
         FIG. 19  is a sectional view taken through a side wall of the shipping container shown in  FIG. 1 ; and 
         FIG. 20  is a sectional view taken through an end wall of the shipping container shown in  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to the drawings and in particular to  FIG. 1 , there is shown a wall insulating system, generally designated  100 . The insulating system  100  is especially suited for mounting to a shipping container, generally designated  1000 . It can be appreciated however that the system  100  of the present invention may be adapted to other types of applications with a complementary non-planar mounting surface. 
     Shipping containers  1000  are generally rectangular with a floor  1002 , side walls  1004 , doors  1006 , an end wall  1008  and a roof  1010 . A standard container is typically 40 feet or 20 feet long, 8 feet 6 inches high and 8 feet wide. Shipping containers are generally made of metal with at least the side walls  1004  and the end wall  1008  configured with a corrugated cross-section to increase the strength of the walls. The corrugations typically have a depth of 1.25 inches up to 2 inches. Corner posts  1012  provide added support for the container  1000  and sufficient support for lifting the container. Bottom frame members  1014  may include openings  1016  for forklift tines or straps. 
     The insulating system  100  is formed of interconnected panels  120 , described hereinafter, that mount to the walls  1004  with glue or conventional fasteners. A finishing layer, such as paneling, drywall or other finishing treatments mounts with fasteners, glue or other conventional mounting techniques to the insulating panels  120 . For some applications, a coating such as paint, wallpaper or other final, exposed material that is visible may cover certain finishing layers, such as drywall. The system of the present invention provides for elimination of the conventional stud framing and roll-type insulation being added to a shipping container  1000  and provides improved R-value in a thinner layer, adding floor space and volume to the finished interior of a shipping container. In addition, the present invention is less expensive and easier to install than prior conventional building systems and techniques. 
     The insulating system  100  is formed from interconnected rectangular insulating panels  120  mounted in an edge-to-edge relationship. As shown in  FIGS. 2-8 , the panels  120  are generally rectangular and include tongues  140  and complementary grooves  142 , such as shown most clearly in  FIGS. 2 and 4 , along the top and bottom surface and the ends of the panel  120 . The tongues and grooves  140  and  142  provide for alignment and connection along both the horizontal and vertical edges so that the panels  120  may be connected to extend horizontally and vertically in a continuous insulating layer. The panels  120  also include alignment tabs  144  and complementary notches  146  along the top and bottom edges that aid in aligning the panels for final orientation. In one embodiment, the panels  120  are made of a closed cell expanded polystyrene material. Such a material is lightweight, provides excellent insulation performance and is impervious to water. Moreover, such material may include a fire retarder. Although a vapor barrier may also be added to the system, it can be appreciated that with the insulating layer  104  made of a water impervious material and with interlocking edges, the need for a separate vapor barrier used in many applications may be eliminated. 
     Referring again to  FIGS. 2-6 , each of the panels  120  includes a generally planar outer face  122  having a series of parallel passages  128  that may serve as wiring chases or for running tubing, fiber optics or other elements through the insulating layer without requiring cutting into the panels  120 . Indicator lines  124  are aligned with the passages  128  and a centerline  125  acts as a cutting line for cutting the panels  120  into even halves. The passages  128  also allow for water to drain. When the panels  120  are attached, horizontally extending channels  126  are formed. The horizontal channels  126  bypass the vertical passages  128  so that utilities may be run in both directions without intersecting. The vertical passages  128  provide for easy insertion and routing of wiring, tubing and other elements that are typically placed inside walls. In some embodiments, the small section of panel foam between the horizontal channel  126  and the vertical passage  128  may be removed so the channels  126  and the passages  128  connect. A cutting guide may provide for trimming the panels  120  to a common size and provides a guide for forming a straight edge. It can be appreciated that in one embodiment, the panels are approximately 44 inches wide and 24 inches high (122×61 cm). A typical depth for a panel  120  is two inches (5 cm) at the narrower section and about 3.25 inches at the deepest depth of a corrugation. Such a size provides for standard alignment and easily transporting the panels  120  down narrow staircases such as often lead to a basement. 
     The panels  120  also include mounting elements  150  that serve as studs embedded into the panels. In one embodiment, each panel  120  includes two embedded mounting elements  150 . The mounting elements  150  extend vertically when the panels  120  are installed. The mounting elements  150  may be placed at conventional spacing such as at 16 inch (41 cm) centers or varying on center spacing such as approximately 22 inch centers as is typical with wood stud construction. The mounting elements  150  extend to a first face of the panels  120  and provide a surface for gluing as well as receiving conventional fasteners such as bolts, screws and/or nails. The mounting elements  150  are lightweight, but provide rigidity and strength to the panels  120 . 
     As shown in  FIGS. 9-11 , each mounting element  150  is a substantially elongate, molded plastic element with a generally “H” shaped cross-sectional profile. The mounting element  150  includes a first mounting portion  152 , a second opposed mounting portion  160 , and a series of central ribs  154  connecting the first portion  152  and the second portion  160 . The first portion  152  extends laterally outward from the ribs  154  at a generally right angle. The ribs  154  may also be configured with portions extending generally diagonally in tension or compression between the first portion  152  and the second portion  160  to aid in transferring loads between the faces. A first face of the first portion  152  includes a glue channel  153  or glue channels transverse to the longitudinal direction. The second mounting portion  160  extends from either side of the center ribs  154 . The second portion  160  also includes transverse channels  156  on an outer face and substantially extending transverse to the longitudinal axis of the mounting element  150 . The outer channels  156  may also serve as glue channels for mounting. 
     Referring again to  FIGS. 2-8 , to mount to corrugated walls, such as side walls  1004  of a shipping container, an inner mounting face  130  of each panel  120  has a corrugated surface that is complementary to the corrugated surface of the side walls  1004 . The corrugated mounting surface  130  includes protruding portions  132  alternating with recesses  134 . The protruding portions  132  include a planar face  136  and tapering connection surfaces  138  that lead from the protruding planar face  136  to the planar face of the inner recess  134  and are orthogonal to the faces  134  and  136 . The inner recessed surface  134  and the planar faces  136  of the protruding portions  132  are generally parallel to one another and to the exposed surface on the opposite side of each panel  120 . The protruding portions  132 , the recesses  134  and the connection surfaces extend generally vertically to align with the complementary portions of the corrugated walls of the shipping container  1000 . The configuration of the panels  120  provides a tight fit against the corrugated walls  1004  without gaps as shown in  FIGS. 12 and 16-18 . 
     As shown in  FIGS. 19 and 20 , the side walls  1004  and the end walls  1008  may have a different corrugation pattern with slightly different dimensions and angles for the protruding portions and the recesses. The panels  120  may be configured with a mounting surface that fits the particular corrugation pattern of the wall to which it is mounted. Moreover, as the walls  1004  are symmetrical, the panels  120  may mount to either the interior or the exterior surface of a corrugated wall  1004 . 
     The mounting elements  150  are spaced apart generally at common intervals such as 8 inches, 12 inches or 16 inches, or at 11 inches or 22 inches or other standard spacing for shipping container corrugations, and provide a lightweight yet durable surface for receiving mounting hardware, as discussed above. The mounting elements  150  are also lightweight and molded and impervious to water for durable and inexpensive construction. It can be appreciated that the system of the present invention reduces the likelihood for water damage, mold and other problems that conventional systems are prone to, especially when the shipping container  1004  is in a damp environment. It can further be appreciated that the present invention provides for easy trimming and cutting with a hand saw or simple knife. The materials used are not irritating to skin or eyes and do not require special gloves for handling as is needed for fiberglass systems. The materials are lightweight and of a size that is easier to handle than typical long wood studs and 4 feet by 8 feet sheets of drywall. Drywall does not need to be aligned with studs as is required with conventional techniques. Installation is much quicker and does not require special skills or tools. 
     The insulating system  100  of the present invention is also easy to install. Little preparation is needed but drain tile, if necessary, is installed before the system is in place. A bead of construction adhesive is placed in the gluing channels  153  on the studs  150  on each panel  120 . Installation generally starts in a lower corner of the wall  1004  with the panel  120  simply pressed onto the inner face of a side wall  1004  or end wall  1008 . The panel  120  is then secured with an adhesive or conventional mounting hardware. Installation continues with the panels  120  until a level of panels  120  is completed. The panels  120  of an adjacent level are aligned with vertically extending tongues  140  inserting into corresponding grooves  142  until a bottom row of panels  120  extends across the wall. The panels  120  of the next row are generally offset from the previous row and placed starting along one edge and working along the row in a similar manner. The mounting elements  150  are aligned by the alignment tabs  144  inserting into the corresponding notches  146 . The panels  120  are configured so that the passages  128  must align. Construction continues along horizontal rows until the entire surface of a wall is covered. The corners are accommodated by cutting off the tongues and/or grooves and butting the panels  120  together. 
     Spaces for receiving electrical boxes can be cut into the panels  120  using a standard drywall keyhole saw. Wiring and other elements can be run through the insulation system panels  120  by leading the wiring through the passages  128  and the channels  126 . When the panels  120  have been installed, the glue is generally allowed to dry for a period of time such as 24 hours. Once the glue sets, the drywall can be applied to the planar outer face  122  by using standard drywall screws attaching to the mounting elements  150 . The insulation system  100  is finished in the same manner as conventional walls with mud and tape used with the drywall and an inner layer such as paint or wallpaper applied over the drywall. In some applications, paneling or other materials may be used rather than drywall. The method is typically faster and easier with less skill and fewer tools required than conventional construction techniques. 
     It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.