Insulated wall panel apparatuses, systems, and methods

Abstract

Methods, systems, and apparatuses for providing insulation for a wall panel, an embodiment of an insulated wall panel including a weather barrier, an insulating layer abutting the weather barrier, a moisture barrier abutting the insulating layer, and structural layer abutting the moisture barrier, and possibly a second insulating layer abutting the structural layer. The insulated wall panel may also include a plurality of nails, each nail having a head embedded in the insulating wall panel abutting the structural layer. A nail gun including a barrel with a toothed end or an end with an adjacent having a flat outer side may propel the nail into the insulating wall panel.

What is claimed is: 
     
         1 . An insulated wall panel, comprising:
 a weather barrier;   an insulating layer abutting the weather barrier;   a moisture barrier abutting the insulating layer;   a structural layer abutting the moisture barrier, the moisture barrier between the insulating layer and the structural layer;   and a fastener including a first head and a second head, and wherein the first head is in contact with and seated against the structural layer and the second head is embedded in the insulated wall panel.   
     
     
         2 . The insulated wall panel of  claim 1 , further comprising at least one stud abutting the structural layer. 
     
     
         3 . The insulated wall panel of  claim 1 , further comprising a second insulating layer abutting the structural layer. 
     
     
         4 . The insulated wall panel of  claim 3 , further comprising a plurality of studs abutting the structural layer, the second insulating layer comprising a plurality of insulation panels, at least one of the plurality of studs extending between two of the plurality of insulation panels. 
     
     
         5 . The insulated wall panel of  claim 3 , the second insulating layer comprising fiberglass batt having at least a R- 13  total value. 
     
     
         6 . The insulated wall panel of  claim 1 , wherein the fastener is one of a screw and a nail. 
     
     
         7 . The insulated wall panel of  claim 1 , the weather barrier comprising a polypropylene film. 
     
     
         8 . The insulated wall panel of  claim 1 , the insulating layer comprising expanded polystyrene having at least a R- 5  total value. 
     
     
         9 . The insulated wall panel of  claim 1 , the moisture barrier comprising polyurethane. 
     
     
         10 . The insulated wall panel of  claim 1 , the structural layer comprising oriented strand board. 
     
     
         11 . An insulated wall panel, comprising:
 an insulating layer;   a moisture barrier abutting the insulating layer;   a structural layer abutting the moisture barrier;   a plurality of studs abutting the structural layer;   a plurality of insulating panels abutting the structural layer, each of the plurality of insulating panels positioned between two of the plurality of studs;   and a plurality of fasteners, each of the plurality of fasteners including a first head and second head, each first head embedded in the insulated wall panel such that the first head is in contact with and seated against the structural layer and the second head is embedded in the insulated wall panel.   
     
     
         12 . The insulated wall panel of  claim 13 , wherein each of the plurality of fasteners is one of a nail and a screw. 
     
     
         13 . The insulated wall panel of  claim 13 , further comprising a base plate and a header plate. 
     
     
         14 . The insulated wall panel of  claim 15 , each of the plurality of fasteners extends into one of the plurality of studs. 
     
     
         15 . The insulated wall panel of  claim 15 , further comprising a second base plate. 
     
     
         16 . The insulated wall panel of  claim 13 , further comprising a weather barrier, the weather barrier abutting the insulating layer. 
     
     
         17 . An insulated wall panel, consisting of:
 a weather barrier;   an insulating layer abutting the weather barrier;   a moisture barrier abutting the insulating layer;   a structural layer abutting the moisture barrier, the moisture barrier between the insulating layer and the structural layer;   a plurality of studs abutting the structural layer;   a second insulating layer comprising a plurality of insulating panels, each of the plurality of insulating panels positioned between two of the plurality of studs; and   a plurality of fasteners each comprising a first head and second head spaced at least 3/16 of an inch apart, each of the plurality of fasteners embedded in the insulated wall panel such that for each fastener, the fastener extends into the stud and the first head is in contact with and seated against the structural layer and the second head is embedded in the insulated wall panel   
     
     
         18 . The insulated wall panel of  claim 17 , wherein each of the plurality of fasteners is one of a nail and a screw. 
     
     
         18 . The insulated wall panel of  claim 17 , wherein the insulating layer is comprised of expanded polystyrene and the structural layer is oriented strand board. 
     
     
         20 . The insulated wall panel of  claim 17 , wherein the weather barrier is polypropylene film and the moisture barrier layer is comprised of polyurethane.