Continuous wall assemblies and methods

摘要

According to one embodiment, an insulated structure includes a frame comprising a plurality of wall studs coupled together and a plurality of foam boards attached to the frame to form a continuous insulative wall. A plurality of fasteners attaches the foam boards to the frame. Each fastener includes an elongate shaft and a cap. The elongate shaft is configured to penetrate through a foam board and into a wall stud to couple the components together. The cap is configured to be positioned atop a foam board to distribute a load relatively evenly to the foam board. A sealing tape is applied across seams between adjacent foam boards and over the fasteners' caps to seal the wall. A sealing caulk is applied to secondary fasteners and penetrations to seal the wall. In some embodiments, the structure has a fastener density of about 1 fastener per 243 in2 of foam board.

主权项

1. A method for providing a continuously insulated wall, the method comprising:
providing a frame comprising a plurality of structural support members coupled together, the frame comprising a plurality of cavities defined by adjacent structural support members; positioning a plurality of insulative foam boards directly against the frame so as to form a continuous insulative wall or surface of the structure, wherein a gap exists between adjacent insulative foam boards; coupling the plurality of insulative foam boards directly to the frame via a plurality of fasteners having an elongate shaft that penetrates through a respective insulative foam board and into a respective structural support member so as to attach the respective insulative foam board directly to the respective structural support member, the fastener including a separate cap having a 1 to 4 inch diameter and having a recess within which the elongate shaft is inserted such that a proximal end of the elongate shaft is flush or recessed below a top surface of the cap, the cap being positioned atop the respective insulative foam board when the elongate shaft is inserted through the respective insulative foam board and into a respective structural support member so as to distribute an applied load relatively evenly to the insulative foam board, wherein a shape of the cap is configured to block insertion of the cap into the insulative foam board and overinsertion of the elongate shaft into the insulative foam board, and wherein the fasteners are applied to the insulative foam board so as to have a spacing between each adjacent fastener of at least 16 inches; and applying a sealing tape having a tape width of about 4 inches over the gaps between adjacent insulative foam boards and over the cap of each fastener so as to seal the exterior wall such that the exterior wall forms an air barrier to restrict a passage of air through the wall to less than about 0.2 L/(s-m2) at a pressure of 75 Pa, the sealing tape comprising a stretchable plastic film with an acrylic adhesive, the sealing tape being elastic so as to have greater than 100% strain capability in both the machine direction and cross machine direction; wherein the continuously insulated wall provides an air barrier and is free of insulative materials positioned within the plurality of cavities defined by adjacent structural support members.