Method of applying foam compositions

Abstract

Methods of applying a foam composition to a cavity in a building structure are provided. The methods include introducing a foam composition into a cavity defined by a wall, a plurality of structural members, and a plastic membrane affixed to one or more faces of the structural members and one or more sides of the structural members defining the cavity.

1 . A method of applying a foam composition to a structure including a first wall, a first structural member, a second structural member opposite the first structural member, an upper structural member, and a lower structural member, the method comprising:
 affixing a plastic membrane to a face of each of the first and second structural members, a face of the upper structural member, and a face of the lower structural member;   stretching the plastic membrane around the opposite sides of each of the first and second structural members to tighten the membrane over a space between the first and second structural members;   affixing the plastic membrane to the opposite sides of each of the first and second structural members; and   introducing a foam composition into a cavity defined by the first wall, the first structural member, the second structural member, the upper structural member, the lower structural member, and the plastic membrane.   
     
     
         2 . The method of  claim 1 , wherein the plastic membrane has a first edge, a second edge, a third edge, and a fourth edge, wherein the first edge of the plastic membrane is affixed to the upper structural member, the second edge of the plastic membrane is affixed to the lower structural member, the third edge of the plastic membrane is affixed to the first structural member, and the fourth edge of the plastic membrane is affixed to the second structural member. 
     
     
         3 . The method of  claim 1 , wherein the plastic membrane is affixed to the first and second structural members along the length of the structural members between the upper and lower structural members. 
     
     
         4 . The method of  claim 1 , wherein the plastic membrane is affixed to the faces of the structural members with staples. 
     
     
         5 . The method of  claim 4 , wherein the staples are located about 0.1 inch to about 2 inches apart from each other along the face of the structural members. 
     
     
         6 . The method of  claim 1 , wherein the plastic membrane is affixed to the sides of the first and second structural members with staples. 
     
     
         7 . The method of  claim 6 , wherein the staples that affix the plastic membrane to the sides of the first and second structural members are inset on the sides of the first and second structural members about 0.3 inch to about 1 inch back from the face of the first and second structural members. 
     
     
         8 . The method of  claim 1 , wherein the staples that affix the plastic membrane to the sides of the first and second structural members are located about 0.5 inch to about 3 inches apart from each other along the side of the first and second structural members. 
     
     
         9 . The method of  claim 1 , wherein the plastic membrane is a poly membrane. 
     
     
         10 . The method of  claim 1 , wherein the plastic membrane is a polyethylene or polypropylene membrane, a fiber reinforced polyethylene or polypropylene membrane, or a spunbond material. 
     
     
         11 . The method of  claim 1 , wherein the plastic membrane has a tensile strength of about 10 lbf/inch to about 150 lbf/inch. 
     
     
         12 . The method of  claim 1 , wherein the foam is an open cell polyurethane foam. 
     
     
         13 . The method of  claim 1 , wherein the foam is an open cell self-compressing polyurethane foam. 
     
     
         14 . The method of  claim 1 , wherein the foam composition as filled into the cavity presents a convex shape. 
     
     
         15 . The method of  claim 1 , wherein introducing the foam composition into the cavity comprises spraying or injecting the foam into the cavity. 
     
     
         16 . The method of  claim 1 , wherein introducing the foam composition into the cavity comprises piercing the plastic membrane with a spray foam gun with a spray tip and applying the foam composition into the cavity. 
     
     
         17 . The method of  claim 1 , wherein introducing the foam composition into the cavity comprises applying the foam in increments to provide a foam having a length of about 3 feet along the first and second structural members. 
     
     
         18 . The method of  claim 1 , wherein the foam composition has a lower operating limit of about 70° F. and an upper operating limit of about 160° F. 
     
     
         19 . The method of  claim 1 , wherein the foam composition does not substantially extend beyond a plane defined by the faces of the first and second structural members. 
     
     
         20 . The method of  claim 1 , wherein the amount of waste foam is less than or equal to 15%. 
     
     
         21 . The method of  claim 1 , wherein the cavity is a building cavity. 
     
     
         22 . The method of  claim 1 , wherein the first and second structural members are vertical structural members. 
     
     
         23 . The method of  claim 1 , wherein the upper and lower structural members are horizontal structural members. 
     
     
         24 . The method of  claim 1 , wherein a rigid shield or metal screen configured to overlay the plastic membrane is not used in the method. 
     
     
         25 . The method of  claim 1 , wherein the foam is not applied to the faces of the structural members. 
     
     
         26 . The method of  claim 1 , wherein drywall is directly applied to the cavity or cavities after introduction of the foam. 
     
     
         27 . (canceled) 
     
     
         28 . The method of  claim 1 , wherein the foam composition is applied in increments into the cavity to build 3 foot high columns of foam in each cavity. 
     
     
         29 . A building structure comprising:
 a cavity defined by
 a first wall; 
 a first structural member having a face and sides; 
 a second structural member having a face and sides; 
 an upper structural member having a face; 
 a lower structural member having a face; and 
 a plastic membrane affixed to at least one of the face of the first structural member, the face of the second structural member, the face of the upper structural member, and the face of the lower structural member, the plastic membrane also being stretched around the opposite sides of each of the first and second structural members, and affixed to the opposite sides of the first and second structural members, to tighten the membrane over a space between the first and second structural members; and 
   a foam composition in at least a portion of the cavity, the foam composition imparting structural or insulation support.   
     
     
         30 . The building structure of  claim 29 , wherein the plastic membrane is affixed to the face of the first structural member, the face of the second structural member, the face of the upper structural member, the face of the lower structural member, and the opposite sides of each of the first and second structural members.