Note: Descriptions are shown in the official language in which they were submitted.
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SYSTEM ~OR SUPPORTING AND RETAINING INSULATION
Techlical Field
This invention relates to a new system for supporting
and retaining insulation in the form of batt, sheet, roll,
or rigid panel insulation on a wall, ceiling, partition or
other structure surface.
Background Art
A number of methods are used for supporting and
retaining fiber insulation batts, sheets, and rolls between
studs or in other voids to be insulated on walls, ceilings 9
partitions, and other structure surfaces. Typically, fiber
insulation batts, sheets, and rolls are manufactured with
paper flanges which are tacked or stapled to wooden studs
of the wall or beams of a ceiling or floor. A disadvantage
of this conventional approach is that the fiber insulation
tends to sag over time and part with the paper flanges.
Further, this method is not suitable for steel buildings,
metal wall studs, and metal roofs and floors.
According to another approach, metal nail-like prongs
or bars are secured at right angles to the wall or other
surface of the void to be insulated. A disadvantage of the
nail-like prongs or bars is that they create a ha~ardous
environment at the workplace location creating a risk for
workers. The nail-like spikes are incorporated in a frame
which is limited for use with studs of a particular
c,n-center spacing. The approach is not well adapted for
variable spacing or for masonry walls and metal walls.
The closest prior art of which applicant is aware is
the Miller U.S. Patent No. 1,915,611 for a prefabricated
insulating slab comprising 2 pl aniform l;eeper with prongs
issuing or extellding outwardly from each side of the plane
of the keeper. The keeper functions as a supporting shee~
with an insulation bod~ ir,lbedded cn tlle prongs on each side
to forrn the prefabricated insulating slab. The supporting
sheet or keeper is not applicable for supporting fiber
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insulation batts or sheets on a wall, ceiling, or partition and
functions only as the internal binding support for fibrous mat-
erial bodies of one-half the thickness of the slab, sandwiched
and imbedded on either side. Furthermore, the issuing or ex.tendiIIg
prongs are not appropriately adapted initially to lie flush
with the plane of the support member or keeper during installation,
to be bent outwardly thereafter by an installation worker. The
prongs of the type contemplated by Miller would have to be
extended by machine during manufacture. Nor are the prongs in
the configuration of elongate arrows with at least one barb
on -the free end to facilitate securing and retaining fiber
insulation bat:ts or sheets impaled on the prongs. Overall, the
support device of Miller is not appropriately structured and
therefore is inapplicable for supporting fiber insulation batts,
sheets, rolls or panels in the voids of a wall, ceiling, par
tition or other structure surface. The Hugh U.S. Patent No.
1,520,026 pertains to a nail band having dimensions and s~ructures
entirely inappropriate for supporting thick fiber insulation batts
and sheets.
ummary of the Invention
Therefore, the prese~nt invention seeks to provide
a new apparatus and system for supporting and retaining
insulation for either thermal insulation or sound control,
in the form of batt, sheet, roll, or rigid panel board in~
sulation; and to provide a system applicable for use on a
wall, ceiling, partition or other structure surface which
is easily installed on any material building surface and
which securely retains the insulation material against sagging
or parting.
The invention also seeks to provide apparatus and
system for supporting and retaining insula-tion which may be
installed initially in a form which does not present risks
to workers and which does not create a hazardous environment.
Thereafter, the form of the support system may be readily
converted by workers at the site to appropriate configuration
for supporting and retaining insulation as it is installed.
Still further, the invention seeks to provide app~ratus and
system for ~upporting and retainlng insulation whieh may be
readily manufactured in quantity and s~ored and 8hipped in
compact form for rapid ins~allat~on and preparation at the
building site. The system is sufficiently flexible for use
with any bullding sys~em, or any on-center spacing of
~tud~ 9 rafters or beams.
Disclosure of the Invention
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In order to accomplish these results, the pres~nt
lo invention provides a ~ys~em of flange base pla~e~
con~tructed and arr~nged with a flat bearing are portion
for bearing against a structure surface such as a wall,
ceiling or partition. ~he flange base plates are formed
with an~ of a variety of means for securlng ~he bearing
15 face to the structure surace~ The flange base plates are
formed with oRe or more elongate lnsulstion suppor~ mem~er~
havin~ a free end and ~ stem end merging with the flange
base plate. ~he insulation support members are foldable at
the stem end to extend at an angle frvm the flange base
20 ~lste for supporting fiber insulation. Each elongate
supp~rt member is formed with a declining taper at the frec
end for impaling and supporting insulation on the support
member and with at least one barb at the free end for
retaining the impaled insulation.
2s A feature and advantage of the invention ~ that the
elongate insulation suppor~ members are initially fonmed
generally in the same plane with the flange base plate for
installation of ~he flange ba~e plate on a structure
surface with the elongate insulation support members lying
30 in substantially the same plane of the s~ructure surface.
This safety fea~ure affords a safe environment for workers
at the site, and installation workers may subsequen~ly fold
the elongate insulation support at an angle proj ecting from
the flange base plates for support of insulation upon
35 ins~callation. Retaining washers may also be used comprised
of a fla~ retaining surface with a~ leas~ one slot for
receiving an elongate support membPr and engaging the barb
at an edge of the slo~. The retaining ~asher therefore
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bears against -the thermal insulation or sound control materials
impaled on the elongate support member.
The flange base plates may be secured to a structure
surface in a number of ways. According to one er~odiment of
the invention, the flange base plate is provided with an
adhesive layer on -the flat bearing surface for adhering to a
structure surface of any of a variety of materials. Alter-
natively, or additionally, the flange base plate means is
formed wlth spaced holes for receiving nails, screws, or
other securing members. The invention is thus adap-ted for any
building system or for any on-center spacing of structural
building materials.
According to one system embodiment, the invention is
divided into a number of individual flange base plates, for
example, of circular or rectangular configuration, each formed
with a single elongate insulation support member. The elongate
support member is initially flush with the individual plate but
foldable at the stem after installation. In this manner, a
large number of individual base plate bearing surfaces may be
secured over a structure surface such as wall, ceiling or
partition for supporting and holding insulation. The individual
plates may be formed with an adhesive layer to facilitate
securing and distributing the plates over the wall.
The invention contemplates a variety of other configur-
ations for the system. For example, the flange base plate maycomprise an elongate strip formed with a row of elongate support
mem~ers with the elongate axes directed parallel with the elong
ate direction of the strip. An advantage of this configuration
is that the strips may be rolled into a roll of multiple con-
tiguous turns for compact storage and shipping. The insulationsupport members are maintained flush with the strip during storage,
shipping and initial installation and are thereafter folded at an
angle to the structure surface for supporting insulation.
According to other configurations, the flange base plate
may comprise a Eurring strip suitable for application of
its flat bearing surfaces to, for example, masonry walls.
Similarly, the flange base plates may be in the
configuration of purlin runners for supporting ceiling
insulation.
In yet another embodiment, the inven-tion provides
a plurality of metal studs formed with the elongate support
members as an integral part of the stud to be Eolded outwardly
at an angle for supporting insulation in i:he space or void be-
tween studs.
The invention in one aspect pertains to apparatus
for use in building insulation systems for supporting and re~
taining fiber insulation in the form of batt, sheet, roll or
panel insulation on a wall, ceiling, partition or other structure
surface of a building. The apparatus comprises flange base plate
means constructed and arranged with a flat bearing face portion
for bearing against a structure surface of the building, the
flange base plate means formed with means for securing the bearing
face to a structure surfaceO At least one elongate insulation
support member is formed in the flange base plate means and
has a free end and a stem end merging with the flange base plate
means, the insulation support member being constructed and
arranged to be manually foldable at the stem end to extend
at an angle from the flange base plate means for supporting
insulation. The elongate insulation support memb~r is formed
with a declining taper at the free end for impaling and supporting
insulation on the support member, and the elongate support member
also is formed with at least one barb at the free end for retain-
ing insulation impaled thereon. The elongate insulation support
member is initially formed generally in the same plane with the
flange base plate means for installation oE the flange base
plate means on a structure surface with the elongate insulation
support members lying in substantially the plane of the flange
base plate means for safety of persons at the workplace whereby
installation wor~ers may subsequently fold the elongate insulation
support members at an angle projecting from the flange base plate
means for support of insulation upon installation of the
insulation.
The invention also comprehends a method for installing
and supporting fiber insulation in the form of batt, sheet, roll
or panel insulation on a wall, ceiling~ partition or other
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structure surface of a building including providiny a plurality
of flange base plates constructed and arranged with a flat
bearing face portion for bearing and fastening against a structure
surface of a building, each flange base plate being formed
with at least one elongate insulation support member and each
insulation support member having a free end and a s-tem end
merging with the flange base plate and being formed with
sufficient length from the stem end to the free end to match
substantially the thickness of the fiber insulation to be
installed and supported. Each insulation support member is
constructed and arranged to be manually foldable at the stem
end by instal].ation workers to extend at an angle from the
flange base plate for supporting insulation and each elongate
support member is formed with a declining taper at the free end
for impaling fiber insulation, and with at least one barb
providing an arrowhead configuration at the tip of the free end
for retaining insulation. The method further includes applying
and fastening the plurality of flange base plates at spaced
apart intervals on the structure surface of a building to be
insulated with the respective flat bearing face portions
bearing against the structure surface and maintaining the in-
sulation support members substantially in the plane of the
respective flange base plates and the structure surface during
the period prior to installation of insulation for safety of
persons at the workplace. ~ach of the insulation support members
to be used for supporting insulation is manually folded at
an angle relative to the respective flange base plate by grasping
each insulation support member and bending the insulation
support member at the stem end so that the free end is directed
away from the respective flange base plate and structure surface
substantially normal to the flange base plate. Fiber insulation
from batts, sheets, rolls or panels is installed by impaling
the fiber insulation on the outwardly folded insulation support
members of the respective flange base plates, the fiber in-
sulation being supported over desired areas of the structuresurface on the insulation support members and retained on
the barbs of the support members.
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Other aspects, features and advantages of -the present
invention will become apparent in the following specification
and accompanying drawings.
Brief_Descr~ptlon of ~he Drswin~s
Figure 1 ~s perspective vlew of a system for
supporting and retaining fiber insulation in a strip
coniguration according to the invention ~hile Figure lA is
a plan view of the insulation supporting and retaining
strip in a compact roll for storage and shippingO
Figure 2 is a perspective view of the insulation
supporting and retai~ing strip in place on 8 wall in
preparation or installing insulation, either thermal
insulation or sound cQntrol materi ls.
Figur~ 3 is a fragmentary persp~ctive view of a
furring strip configuration of the insulation supporting
and retaining systemO
Figure 4 is a pl an view of 2n individual flange base
platP embodimen~ of the present invention with the
insulation support member 1ush with the plate for
placement on a struc~ure surface; while Figure ~ shows the
insulation support member folded at the stem for impaling
insulation.
Figure 4B is a partial side cross section of the
individual flang~ base plate of the type illustrated in
Figure 4A with the addition of an adhesive layer.
Figure 5 is a diagrammatic view of an individual
support of the type illustrated in Figure 4A showing the
use of a slotted retaining washer.
Figure 6 is a plan view of an alternate retaining
washer.
Figure 7 is a plan view of an individual support
having a support member with a single barb.
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Figure 8 is a fragmerltary perspective view of a metal
stud insulation supporting and retaining system while
Figure 8A is a cross sectional view through the stud.
Figure 8B is a fragmentary perspective view of another
metal stud insulation supporting and retaining system.
Figure 9 is a diagrammatic view of an elongate
insulation support member according to the invention having
a double fold or bend for retaining insulationrappearing with
Figures 4B, 5, 6 and 7
Descrintion of Preferred Exam~le Embodiments and B~st Mode
r
10 of the Invention
A strip configuration insulation supporting and
retaining system is illustra~ed in Figures 1, lA, and 2.
The strip configuration support system 10 is composed of a
flat strip 12 which functions as the flange base plate for
15 elongate support members 14 in the configuration of an
arrow punched or cut in the strip 12. Each elongate
support member 14 therefore has a free end 15 in the
configuration of an arrowhead with double barbs and a stem
end 16 merging wlth the strip 12. Prior to installation on
20 a wall or other structure surface and after installation
but before insulation is applied, the elongate support
members or arrows 14 remain flush with the strip 12 as
indicated by the unfolded arrow 18.
The s~rip 12 functions as a flange base plate for the
25 support system and the undersurface of the strip 12 forms a
bearing face applied to a wall, ceiling, partition or other
structure surface 20 as illustrated in Figure 2. In this
application the strips 10 are applied to the wall 20
between studs 22 before the studs are set in place. At
30 this time the elongate support members or arrows 14 remain
in the plane of the strip generally flush with the wall so
as not to subject workers to unnecessary hazards. Prior to
application of the insulation 24 which may be, for example,
in the for~ of sheet, batt, or roll insulation, the arrows
3~ or members 14 are folded outward from the stem end 16 at an
angle from a strip in the wall for impaling the insulation
24 as i~ is applied.
For support of the insulation 24 without sagging the
strips 1~ are typically applied at intervals, for example,
of four feet providing rows of support members 14 at
intervals of four feet one above the other. The top strip
10 may be, for example, positioned in the order of four
inches (10 cm) to ten inches (25 cm) below the top of the
studs 22. The strips lO are also applied spaced on either
side of seams where one insulation sheet, roll or batt ends
and another begins. The support members or arrows 14 have
a minimum length of ~rom three inches (7.5 cm) to five
inches (12.5 cm) and longer depending upon the width of the
lO insulation. The support members or arrows 14 are ~ypically
spaced, for example, eight inche~ (20 cm) apart along the
strip or a greater density may be used to provide at least
two arrows extending outwardly from the strip between each
pair of studs. The gauge of the flange base plate or strip
15 material may range, for example, from 16 to 26 gauge while
26 gauge metal permits the strip 10 to be readily stored
and shipped in a compact roll as illustrated in Figure lA.
As there shown, the arrows or support members 14 of course
remain flush with the strip 12.
The strip 12 may be securely applied to a wall or
other struc~ure surface in a variety of ways, for example,
the under surface or bearing surface of the flange base
plate strip 12 may be provided with an adhesive layer
exposed by pealing off a protective paper cover for
application to any of a variety of material s~rfaces.
Alternatively, the strip is provided with spaced holes for
application of nails, screws, rivets or other securing
members .
A furring strip embodiment of the support system is
illustrated in Figure 3 applicable for use, for exarnple, on
masonry surfaces. In this embodiment the flange base plate
portion 30 is provided with an elevated rib or furrow 32
with folded bearing faces 33 for application to the support
surface of masonry or other material. The bearing face 33
may be secured by nails, screws, rivets, and adhesive layer
or other means. The elevated rib or plate portion 32 of
the furring strip is formed with the punched or cut out
elongate support members 34 in this example in the same
arrow configuration having a free end 35 in the
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configuration of an arrowhead with a pair of barbs 35a and
35b. During shipping and initial installation, the
elongate support member 34 rests flush with the furrow rib
or plate 32 as shown at 38 and upon application of the
insulation, is first folded or bent at the stem 36 to
project outward at an angle from the flange base plate
furrow strip for împaling insulation as shown in Figure 3.
The insulation support system of the present invention
may also be provided by a plurality of individual flange
10 base plates as illustrated in Figures 4 thru 7. As shown
in Figure 4, the individual elongate support member 44 is
formed by cutting or punching from appropriate gauge metal
sheet along with an individual flange base plate 42. The
elongate support member 44 is thereby formed with a free
15 end 45 in the arrowhead configuration with a pair of barbs
45a and 45b and a stem end 46 which merges with the base
plate 42. The individual base plate and support ~embers 40
may then be distributed over a structure surface defining a
void to be filled with insulation. The flange base plates
20 42 may be secured by, for example, nails, screws, rivets,
etc. through holes 47 and the support member or arrow 44
remains flat, that is substantially coplanar with the
structure surface and flush with the base plate 42 until
the insulation is to be applied. At the time of applying
25 the insulation, the arrow members 44 may be lifted and
folded and bent at the stem end 46 as shown in Figure 4A to
project outward at an angle for impaling and receiving the
insulation.
An alternative arrangement for securing the individual
30 base plates and support members to a wall or other
structure surface is illustrated in Figure 4B where the
base plate and support member 50 comprises a flange base
plate 52 formed with an adhesive layer 53 on the bearing
face for adhesive securing to the surface of the wall,
35 ceiling, or other structure surface. As heretofore
described, the flange base plate 52 is integrally formed
ith the elongate support member 54 having a free end 55 in
the configuration of an arrowhead and a stem end 56 from
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which it is folded or bent outward at an angle rom the
plate 52.
As shown in Figure 5, the individual base plate and
support member 40 of the type illustrated in Figure.s 4 and
5 4A may be provid~d with a retaining washer or disk 48
having a slot 49 for sliding over the support member 44.
The edge 49a of slot 49 engages a barb 45a of the free end
45 of the arrow member 44 for retaining and holding in
place insulation impaled on the arrow member. The washer
10 48 of Figure 5 is provided with a slot 49 having an open
end for sliding over the side of ~he arr4w member. An
alternative washer 58 is shown in Figure 6 with an internal
slot 59 of sufficient width to fit over the arrowhead at
the free end 45 of the support member 44 engaging a barb at
15 either edge of the slot.
Yet another individual flange base plate and support
member 60 is shown in Figure 7 in which the support member
64 having a free end 65 is more in the configuration of a
spear or hook with a single barb 65a. The stem end 66 as
20 heretofore described merges with the flange base plate 62
and the base plate 62 is formed with holes 67 for securing
to a structure surface. It is also apparent that a
combina~ion of securing methods may be used for the
individual base plate support member 60, for example, a
25 combination of an adhesive layer on the bearin~ surface and
nails, screws, ri~ets or other securing members.
The present invention also provides a metal stud
insulation support and retaining system as illustrated in
Figures 8 and 8A. In this system configuration the metal
30 studs 80 themselves comprise the flange base plates in
which the support members 84 are stamped or cut. Each
metal stud 80 includes a major cross sectional dimension
spanned by a plate 82 and a minor cross sectional dimension
span by bearing surfaces 83 which bear agai,nst the walls,
35 partitions, or other structure surfaces. The metal studs
82 may be formed of relatively thin gauge sheet metal, for
example, in the range of 16 to 24 gauge and are formed with
a row of a plurality of elongate support members stamped or
cut in the plate 82 of metal stud 80. As heretofore
7q~6fl~
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described, each elongate support member 84 is provided with
a free end 85 which may be in an arrowhead config~ration
and a stem 86 which merges with the plate 82 of the major
cross sectional dimension of stud 80~ The arrow members 84
may remain flush with the plates 82 following installation
of the studs and when insulation is to be applied in the
voids between the studs the arrow members 84 are then
folded or bended to extend into the space between the studs
and impale the insulation from the sides. In this respect
10 the arrowheads 84 may be designed to be longer than arrow
members projecting at right angles from the wall 20 itself.
Another metal stud configuration is shown in Figure
8B. The metal stud 90 is provided with a side plate 92
having a wider edge or major dimension 93 in which are
15 for~ed the elongate insulation support members or arrows 94
with a free end 95 in an arrowhead configuration and a stem
end 96 which merges with the wider edge 93. Wider edge 93
faces the insulation while narrower edge or minor dimension
57 adds rigidity to the stud 90 as does ridge 93a formed in
20 the wider edge 93.
While the invention has been described with reference
to particular example embodiments, it is apparent that the
system for supporting and retaining insulation may assume a
variety of configurations. For example, the furrow strip
~5 30 of Figure 3 may be adapted to function as purlin runners
for hanging insulation on vertical walls or other structure
surfaces~ Similarly, in any of the embodiments, the free
end 75 of a support member 74 may be folded over ~t a
location 77 below the barbs of the arrowhead in addition to
the fold at the stem end 76 as shown in Figure 9. The
second fold or double fold at location 77 just below the
head at the free end 75 may be used to secure insulation in
place or to secure a retaining washer of the type
illustrated in Figures 5 and 6. In the various embodiments
35 of the invention, the tapered free end of the insulation
support member is provided with a rounded or blunted tip
rather th~n a sharp tip as a further worlc-safety measure.
Furthermore, the invention is applicable for either thermal
insulation or sound control materials in batt, sheet, roll,
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panel, board or other configuration incl~ding either
pliable or rigid materials. In accordance with these
various configurations the invention is intended to cover
all modifications and equivalents within the scope of the
5 following claims.
