Note: Descriptions are shown in the official language in which they were submitted.
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ENCAPSULATED INSULATION ASSEMBLY
BACKGROUND OF THE INVENTION
The present invention relates to an insulation assembLy and;
in particular, to an insulation assembly which includes a
plurality of encapsulated insulation modules that are joined
together by flexible connector strips.
Building structures, such as homes, industrial buildings,
office buildings, mobile homes, prefabricated buildings and
similar structures typically include walls (both interior and
exterior), ceilings, floors and roofs which are insulated for
both thermal and acoustical purposes, especially the exterior
walls and roofs of such structures. The walls, ceilings, floors
and roofs of these structures include spaced-apart framing
members, e.g. studs, rafters, joists, beams and similar support
members, to which sheathing, paneling, lathing, wallboard or
similar structural boarding or sheet materials are secured to
form walls, ceilings, floors and roofs having cavities therein
defined by the framing members and the boarding or sheet
materials.
These cavities typically have standard dimensions, e.g. wall
cavities in homes typically are about ninety three inches high
or long by about fourteen and one-half or twenty two and one-half
inches wide when framed with wooden studs or about sixteen or
twenty four inches wide when framed with metal studs. The
fibrous batts of insulation typically used to thermally and/or
acoustically insulate such cavities are typically about ninety
four inches long by either fifteen or twenty three inches wide
when insulating cavities framed with wooden studs and ninety six
inches long by either sixteen or twenty four inches wide when
insulating cavities framed with metal studs. The fibrous batts
vary in thickness from about three and one half inches to about
six and one half inches. Thus, when the fibrous batts are
installed in such cavities, there is a friction fit between the
batts and the side and end walls of the cavities to help hold the
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fibrous insulation batts in place. In ceilings, floors and roofs
the insulation batts are typically greater than six and one half
inches in thickness and can be much thicker e.g. thirteen inches
or more in thickness.
Fibrous insulation assemblies are currently known wherein
a single binderless fibrous insulation batt is encapsulated
within an envelope, such as a polymeric film, to confine dust and
loose fibers within the insulation assembly and provide a
relatively smooth, non-irritating outer surface on the insulation
assembly for handling. One such insulation assembly is disclosed
in U.S. patent no. 5,277,955; issued January 11, 1994. Whi1e the
patent states that such insulation assemblies can be used to
insulate the walls, ceilings and floors of buildings, there is
a need for insulation assemblies which provide the end user or
installer with greater flexibility at a job site so that shorter
than standard length or height wall cavities and the like can be
insulated with the insulation assemblies without having to cut
open the envelope and utilities and the like, such as electrical
wiring, can pass through the cavities being insulated with the
insulation assemblies without having to cut open the envelope.
BUMMARY OF THE INVENTION
The encapsulated insulation assembly of the present
invention provides a solution to the above needs by providing a
modularized encapsulated insulation assembly that: a) in addition
to being sized to insulate standard length cavities, can be
selectively separated into two or more encapsulated insulation
modules to insulate wall, ceiling, floor or roof cavities shorter
than the standard height or length of such cavities without
cutting open the envelope; b) has spaced apart encapsulated
insulation modules which can be installed in a wall, ceiling,
floor or roof cavity to provide one or more convenient locations
within the cavity being insulated through which electrical wiring
or other utilities can pass without having to cut open the
encapsulating envelope; and c) permits relatively high R value
encapsulated insulation modules to be easily folded over upon
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adjacent modules for packaging and shipment or for providing a
product with an even higher R value.
The encapsulated insulation assembly of the present
invention includes at least two insulation modules, but may
include more than two insulation modules. The insulation modules
of the modularized, encapsulated insulation assembly are each
less than the standard length or height of a wall cavity, but the
combined lengths of the insulation modules preferably equal or
are somewhat greater than the standard length or height of wall
cavities which are about ninety three to ninety six inches in
height or length. In one embodiment of the present invention,
the encapsulated insulation assembly can include a series or
plurality of insulation modules of substantially equal length
which are packaged and shipped in roll form.
Each insulation module includes a compressible, resilient
insulation material encapsulated within a vented, flexible
envelope which overlays and encloses the major and lateral
surfaces of the insulation material and which may also overlay
and enclose the end surfaces of the insulation material. When
the insulation material is otherwise completely enclosed within
the envelope, the envelope is vented, e.g. at the ends, to permit
air to pass through the envelope during compression and recovery
of the insulation module. The insulation modules are joined by
a flexible connector strip which extends between adjacent ends
of the insulation modules and lies either substantially in the
plane of one of the major surfaces of the insulation material or
about midway between the major surfaces of the insulation
material. In one embodiment the connector strip not only
provides a means for selectively separating one or more
encapsulated insulation modules from an encapsulated insulation
assembly, but also provides one or more locations between the
insulation modules of the encapsulated insulation assembly which:
a) permit the passage of electrical wiring, plumbing and other
utilities (hereinafter referred to as "utilities") through the
cavity being insulated without having to cut open the envelopes
of the insulation modules; and b) enclose the utilities between
adjacent ends of the insulation modules. Thus, the encapsulated
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insulation assembly of the present invention can be folded for
shipment and packaging; separated into one or more modules to fit
nonstandard sized cavities; and in certain embodiments, the
modules of the insulation assembly can be folded over upon each
other to form a double thick insulation.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a schematic perspective of a first embodiment of
the encapsulated insulation assembly of the present invention.
Fig. 2 is a schematic side view of the encapsulated
insulation assembly of Fig. 1 folded over so that one module
overlays the other module.
Fig. 3 is a schematic side view of the encapsulated
insulation assembly of Figs. 1 and 2.
Fig. 4 is a schematic side view of the first embodiment of
the encapsulated insulation assembly of the present invention
having more than two insulation modules.
Fig. 5 is a schematic side view of a second embodiment of
the encapsulated insulation assembly of the present invention.
Fig. 6 is a schematic perspective view of a third
embodiment of the encapsulated insulation assembly of the present
invention.
Fig. 7 is a schematic side view of a fourth embodiment of
the encapsulated insulation assembly of the present invention for
accommodating the passage of utilities through the insulation
assembly.
Fig. 8 is a schematic elevation of the framing in a wall
with the encapsulated insulation assembly of Fig. 7 installed and
electrical wiring passing through the wall.
Fig. 9 is an enlarged sectional view taken substantially
along lines 9-9 of Fig. 8 to schematically show electrical wiring
being enclosed between the ends of the insulation modules.
Fig. 10 is a schematic side view of the fifth embodiment of
the encapsulated insulation assembly of the present invention for
accommodating the passage of utilities through the insulation
assembly.
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FIG. 11 is a schematic side view of the encapsulated
insulation assembly of the present invention in roll form.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Figs. 1-6 show a modularized, encapsulated insulation
assembly 20 of the present invention for thermally and/or
acoustically insulating wall, ceiling, floor and roof cavities
of both standard and nonstandard lengths. Each modularized,
encapsulated insulation assembly 20 includes at least two
insulation modules 22 having an insulation material 24
encapsulated within an envelope 26 and may be compressed and
packaged in a flat batt or roll form.
The insulation material 24 is a fibrous, foam or similar
insulation material, but preferably, the insulation material is
a fibrous insulation material, such as conventional glass fiber
insulation material which is both compressible and resilient.
Where a fibrous batt or blanket is used as the insulation
material 24, such as a glass or other mineral fiber batt or
blanket or a polymeric f iber batt or blanket, the f ibers of these
batts or blankets may be bonded together with a binder (e.g.
phenol/formaldehyde resole resins or water deliverable acrylic
based binders), by direct heat bonding between the fibers, or by
other means to give the batt or blanket integrity and resilience
(hereinafter referred to as "bonded fibrous insulation
material"). These batts or blankets can also be binderless or
essentially binderless (i.e. quantitatively less than 1% by
weight binder) with the fibers of these batts or blankets being
held together mainly by fiber entanglement (hereinafter referred
to as "unbonded fibrous insulation material"). In addition to
the preferred insulation materials, the insulation material 24
can also be a polymeric foam insulation material which preferably
is both compressible and resilient.
As shown in Figs. 1-3, 5 and 6 the insulation materials 24,
encapsulated within the envelope 26 of the insulation modules 22,
are typically about forty six to about forty eight inches long
(about one half the height of a standard wall cavity which range
from about ninety three to about ninety six inches long).
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However, for ceiling heights of about one hundred and eight
inches or about one hundred and twenty inches, the lengths of the
insulation modules 20 of FIGS. 1-3, 5 and 6 can be greater.
Typically, the insulation modules 20 are either about fifteen,
sixteen, twenty three or twenty four inches wide (the standard
insulation widths for wall and ceiling or floor cavities). For
encapsulated insulation assemblies 20 having more than two
insulation modules, such as the encapsulated insulation assembly
of Fig. 4, the insulation modules 22 may each have shorter
lengths (preferably, lengths ranging from about thirty two to
about twelve inches long). The insulation materials 24 typically
range in thickness from about three and one half to about six and
one half inches for walls with R values ranging from eleven to
twenty-two and from about six and one half to about thirteen
inches for ceilings and the like with R values of nineteen or
greater.
Preferably, the envelope 26 is a thin pliable or flexible
sheet which may or may not be porous, such as but not limited to,
a polyethylene or other polymeric film; kraft paper; non-woven
fabric; combinations or laminates thereof and similar sheet or
facing materials. A preferred thin polymeric film used for
forming the envelope 26 is an air permeable or impermeable,
pliable film, such as but not limited to, a polyethylene film
about 0.1 to about 1.5 mils thick which may be metalized.
As shown in Figs. 1-11, the envelope 26 encapsulates the
insulation material 24 of each module 22 by overlaying both major
surfaces, the two side edges, and the end edges of the insulation
material at the ends of the insulation modules 22 facing other
of the insulation modules 22 of the encapsulated insulation
assembly 20. As shown in Figs. 1-5, the envelope 26 can overlay
the two outer end edges of the insulation material 24 of the
insulation modules 22 at the opposite ends of the encapsulated
insulation assembly 20 or, as shown in FIG. 6, the two outer end
edges of the insulation material 24 of the insulation modules 22
at the opposite ends of the encapsulated insulation assembly 20
may be exposed.
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As shown in Figs. 1-5, the envelope 26 may include a first
sheet of facing material 28 and a second sheet of facing material
30. These sheets of facing material 28 and 30 are joined
together by an adhesive, a pressure sensitive adhesive, heat
welds or by otherwise securing the sheets of facing material 28
and 30 together at and along end tabs 32, side tabs 34 and
connector strips 36. By encapsulating the insulation material
24 of the modularized, encapsulated insulation assembly 20 within
an envelope 26, dust and/or loose fibers or particles from the
insulation material 24, created during the manufacture,
encapsulating, packaging, shipping, handling and installation of
the modularized, encapsulated insulation assembly 20, are
contained within the envelope 26 thereby reducing the likelihood
of the dust and fibers becoming a possible irritant to the
workers handling and installing the insulation assemblies.
Fig. 6 shows an encapsulated insulation assembly 20 wherein
the envelope 26 is made of a single sheet of facing material 28
which is wrapped completely around the insulation material 24 and
overlapped. The facing material 28 is bonded to itself along the
longitudinally extending overlap 39 and at the connector strips
36 and end tabs, if used, by an adhesive, a pressure sensitive
adhesive, heat welds or by otherwise securing the sheet of facing
material 28 to itself. While the ends of the insulation material
24 in the modules 22 of Fig. 6, facing other modules 22 of the
encapsulated insulation assembly 20, are covered by the envelope
26, the envelope 26, as shown in Fig. 6, does not overlay the two
end edges of the insulation material 24 at the opposite ends of
the encapsulated insulation assembly 20.
Insulation materials, such as the modularized, encapsulated
insulation assemblies 20 of the present invention are normally
compressed for packaging to reduce the volume of the insulation
product for shipping and handling, e.g. the volume of the
insulation materials is reduced by a factor of up to seventeen
to one. The compression of such insulation materials for
packaging typically is accomplished within a few seconds. Thus,
where the ends of the insulation material are also encapsulated,
the envelope 26 is vented, preferably, by using a porous membrane
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or film, such as a non-woven fabric material, or by providing a
series of vent holes 38 in the end walls 40 of the envelope 26
overlaying the end edges of the insulation material 24 to permit
the air to be rapidly discharged from within the envelope 26
during such compression packaging operations. The size and
number of the vent holes 38 in each end wall 40 of the envelope
26 may vary. However, a series of vent holes (between about 1/4
and about 1/2 of an inch in diameter), slits or other venting
means 38 that permit the air to be discharged from the insulation
modules 22 within a few seconds is preferred.
When insulation materials, such as the modularized,
encapsulated insulation assemblies 20, are removed from the
packages in the field, e.g. at the job site, the insulation
assemblies are typically allowed at least twelve minutes to
recover from their compressed state to their nominal thicknesses.
Thus, when the envelope 26 is made in whole or in part from an
air permeable material, the vent holes 38 may be eliminated by
waiting to secure together the end tabs 32 of the end walls 40
of the modularized, encapsulated insulation assemblies 20 after
the assemblies 20 have been compressed in the packaging
operation. The end tabs 32 could be secured together by applying
a pressure sensitive adhesive to the mating faces of the facing
materials in the end tabs and pressing the mating faces of the
end tabs 32 together after the air has been discharged from the
insulation modules 22 in the packaging operation.
In the embodiments of Figs. 1-5, the first sheet of facing
material 28 overlaying one major surface of the insulation
material 24 in each of the insulation modules 22 and the second
sheet of facing material 30 overlaying the other major surface
of the insulation material 24 in each of the insulation modules
22 can be made of the same materials, e.g. both polymeric films
having the same physical characteristics, or different types of
sheets or facing materials, e.g. kraft paper on one major surface
of the insulation material 24 and polymeric film on the other
major surface of the insulation material 24. The side edges and
end edges of the insulation material 24 in each of the insulation
modules 22 of the modularized, encapsulated insulation assembly
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are covered by one sheet of facing material 30, as shown in Fig.
3, or by both of the sheet materials 28 and 30, as shown in Fig.
5.
In one embodiment of the modularized, encapsulated
insulation assembly 20, the sheet of facing material 28 is
selected to have a permeability, such that when the modularized,
encapsulated insulation assembly 20 is folded upon itself, as
shown in Fig. 2, to bring the sheet of facing material 28 of-the
two insulation modules 22 in face to face contact, the combined
double layer of facing material 28 within the folded modularized,
encapsulated insulation assembly 20 will have a permeability
sufficiently high to prevent the double layer of facing material
from functioning as a vapor barrier (generally a permeability of
10 perms or more). This permits the folded modularized,
encapsulated insulation assembly 20, as shown in Fig. 2, to be
used as a double thick layer of insulation. While being
especially useful for encapsulated insulation assemblies 20
having lower R values (e.g. Ril through R19), encapsulated
insulation assemblies having higher R values (e.g. R19 through
R25) can also be folded over to increase their thermal and/or
acoustical performance. The sheet of facing material 30
overlaying the other major surface of the insulation material in
the modularized, encapsulated insulation assembly 20 of this
embodiment can be made of the same facing material as 28 or
another type of facing material.
The end tabs 32, the side tabs 34 and the connector strip
36 joining the facing materials 28 and 30 together can be located
in a plane or substantially in a plane coinciding with one of the
major surfaces of the insulation material 24 or module 22 so that
the modularized, encapsulated insulation assembly 20 folds in
this plane (a face folding assembly as shown in Figs. 1-4 and 6)
or the end tabs 32, the side tabs 34 and the connector strip 36
joining the facing materials 28 and 30 together can be located
in a plane located midway or substantially midway between and
extending parallel to the planes of the major surfaces of the
insulation material 24 or module 22 so that the modularized,
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encapsulated insulation assembly 20 folds in this intermediate
plane (a center folding assembly as shown in Fig. 5).
As shown in Fig. 1, the connector strip 36 of that
embodiment and the connector strip or strips of all of the
embodiments of the invention (connector strips 36, 50 and 68) are
preferably provided with a weakened tear line, such as tear line
42, to permit the two or more insulation modules 22 of the
modularized, encapsulated insulation assembly 20 to be quickly
and easily separated, without tearing or cutting open the
envelope 26 and exposing the encapsulated insulation material 24.
With the weakened tear line 42, the insulation modules 22 can be
separated by merely tearing the connector strip 36 along the
weakened tear line 42. This permits the insulation modules 22
to be quickly and easily separated for insulating wall cavities
that are less than the standard height or length, as well as
floor, ceiling or roof cavities of varying lengths. Preferably,
the weakened tear line 42 is a perforated tear line extending
completely across the connector strip 36.
Figs. 7-9 show an embodiment of the modularized,
encapsulated insulation assembly 20, especially adapted for
insulating walls, which has a first insulation module 44 that is
about three to five times as long as the second insulation module
46. The two insulation modules are sized in length to permit
electrical wiring, plumbing or other utilities to pass through
the cavities being insulated by the assemblies at a convenient
location or height without having to remove any insulation
material or cut open the envelope 26 encapsulating the insulation
material 24 within the insulation modules. Other than the
different lengths of the two insulation modules 44 and 46, this
embodiment of the modularized, encapsulated insul'ation assembly
20 is the same as the embodiment of Figs. 1-6.
The combined lengths of the first insulation module 44 and
the second insulation module 46, excluding the end tabs 48 and
the connector strip 50, equals or about equals the standard
height of a wall cavity e.g. about ninety three to about ninety
six inches. The widths of the first insulation module 44 and the
second insulation module 46, excluding the side tabs 52, equals
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or about equals a standard insulation width for wall cavities,
e.g. about fifteen, sixteen, twenty three or twenty four inches
in width. The insulation materials 24 within the insulation
modules typically range in thickness from about three and one
half to about six and one half inches and have R values ranging
from 11 to 22.
In a preferred form of this embodiment of the invention, the
first or upper insulation module 44 is about sixty to about
eighty four inches in length and the second or lower insulation
module 46 is about twelve to about thirty six inches in length.
While the connector strip 50 can be a center fold strip,
preferably, the connector strip 50 is a face folding strip, as
shown in Figs. 5 and 7, so that the connector strip 50 does not
obstruct the passage of the utilities through the cavity being
insulated.
As shown in Figs. 8 and 9, when a wall or the like is
insulated with the modularized, encapsulated insulation assembly
of Fig. 7, the electrical wiring 54, plumbing or other
utilities can be passed through the cavities 56 insulated by the
20 modularized, encapsulated insulation assemblies without the need
to cut or tear open the encapsulating envelope 26. The
insulation material 24 within the insulation modules 44 and 46
is preferably a compressible and resilient insulation material,
such as glass fiber insulation, and the combined lengths of the
insulation modules 44 and 46 (as discussed above) is preferably
at least equal to and most preferably greater than the height or
length of the wall cavity being insulated. Accordingly, after
the utilities 54 have been passed through the cavity 56 being
insulated between the ends of the two insulation modules 44 and
46, the insulation modules 44 and 46 will expand to bring the
adjacent ends 58 and 60 of the insulation modules 44 and 46
together and enclose the utilities 54 within the modularized,
encapsulated insulation assembly 20 without having to cut open
or tear the envelope 26 encapsulating the insulation material 24.
Fig. 10 shows another embodiment of the modularized,
encapsulated insulation assembly 20, especially adapted for
insulating walls, which has a first insulation module 62 that
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extends for about half or more of the length of the modularized,
encapsulated insulation assembly (e.g. about forty six to about
eighty four inches); and a series or plurality of second
insulation modules 64 that combined extend for the remainder of
the length of the modularized insulation assembly (e.g. from
about twelve to about forty six inches). The second insulation
modules 64 can be uniform in length (e.g. each of the second
modules having a length ranging from about two inches to about
eighteen inches) or the second insulation modules 64 can vary in
length as shown in Fig. 10 with some of the second insulation
modules 64 having greater lengths than other of the second
insulation modules 64 (e.g. as shown in Fig. 10 the longer of the
second insulation modules 64 could be about fifteen to about
eighteen inches and the shorter of the second insulation modules
64 could each be about three to about six inches). Thus, the
first insulation module 62 and the series of second insulation
modules 64 are sized in length to provide a plurality of
locations in the cavity along the length or height of the cavity
where electrical wiring, plumbing or other utilities can be
passed through the cavities being insulated by the insulation
assemblies 20 at a convenient location without having to remove
any insulation material or cut open the envelope 26 encapsulating
the insulation material 24 within the insulation modules. As
with the embodiment of Figs. 7-9, after the utilities have been
passed through the cavity being insulated between the opposed
ends of two of the insulation modules (62-64 or 64-64), the
insulation modules will expand to bring the adjacent or opposed
ends of the insulation modules together and enclose the utilities
within the modularized, encapsulated insulation assembly 20
without having to cut open or tear the envelope 26 encapsulating
the insulation material 24 or create a significant thermal break
in the insulation.
Other than the different lengths of the insulation modules
62 and 64, this embodiment of the modularized, encapsulated
insulation assembly 20 is the same as the embodiment of Figs. 1-
6. The combined lengths of the first insulation module 62 and
the series or plurality of second insulation modules 64,
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excluding the end tabs 66 and the connector strips 68, equals or
about equals the standard height of a wall cavity e.g. about
ninety three to about ninety six inches. The widths of the first
insulation module 62 and the series of second insulation modules
64, excluding the side tabs 70, if any, equals or about equals
a standard insulation width for wall cavities, e.g.. about
fifteen, sixteen, twenty three or twenty four inches in width.
The insulation materials 24 within the insulation modules
typically range in thickness from about three and one half to
about six and one half inches and have R values ranging from 11
to 22. While the connector strips 68 can be center fold strips,
preferably, the connector strips 68 are face folding strips, as
shown in Fig. 10, so that the connector strips 68 do not obstruct
the passage of the utilities through the cavity being insulated.
In describing the invention, certain embodiments have been
used to illustrate the invention and the practices thereof.
However, the invention is not limited to these specific
embodiments as other embodiments and modifications within the
spirit of the invention will readily occur to those skilled in
the art on reading this specification. Thus, the invention is
not intended to be limited to the specific embodiments disclosed,
but is to be limited only by the claims appended hereto.
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