| Thermal imaging technology allows inspectors to view areas of heat loss through the building envelope and the pictures prove conclusively that in virtually all cases, electrical boxes are a primary means for heat to exit the conditioned space and for unconditioned air to enter the building. Evidence suggests that as much as 20% of all air infiltration in a residence is coming from the electrical boxes Method of determining heat losses through electrical outlets - Patent 4167116.
Besides air transfer, heat loss is occurring due to conduction and convection. While the wall is insulated to R-13 or more, thermal resistance at the electrical box is as low as .003. Heat moves like a liquid or gas. Having 3" X 4" holes in the insulation is rather like having those size holes in the hull of a boat, it takes a lot of energy to keep everything in equilibrium when so much heat is being wasted.
Much work has been done in recent years to address the problem, Energy Design Update recommends face mounted electrical boxes for switches and plugs, (November 2007), there are a number of technologies designed to prevent air movement through the electrical box Airtight Electrical Boxes. Carrying the idea forward, a patent has been issued for an enclosure that provides some level of insulation, (especially in a 2' X 6" cavity), while also making the box airtight EnergyBlock. This technology purports to be Energy Star recognized.
During product development of Custom Formed Batts for Fibertek Corporation, our firm noted that there was no way, on the jobsite, to adequately address heat loss through the boxes. Even the Energy Block provided too little insulation when used in a 2" X 4" cavity. We have invented and applied for a patent on the "Insulated Electrical Box."
Our technology utilizes the same laws of physics that are incorporated into a "Dewar's Flask," most are familiar with this technology because they are familiar with a Thermos Bottle. A vacuum or gas filled cavity is manufactured into the side of the box adjacent to the outside wall. The actual insulation ability of the panel is R-13 at .125" thickness and can be increased with additional thickness. The effective R-Value is reduced by conduction of the material at the sides of the panel and overall R-Value must be calculated knowing what that material will be.
We also patented a means of sealing the box against air leakage. This technology involves two layers of film encapsulating a gel that air activates to seal the hole where wires penetrate. The film is rugged and the encapsulation is not subject to tearing when secondary work is done to attach the wires to the plug or switch.
This technology is available for licensing to manufacturers of electrical boxes.
Contact Bill Daviau at 336-601-5911 (billdaviau@aol.com) for further information about licensing. | 
