Note: Descriptions are shown in the official language in which they were submitted.
CA 02361795 2001-11-09
PRE-CUT FIBROUS INSULATION FOR CUSTOM FITTING
BUILDING CAVITIES OF DIFFERENT WIDTHS
This application is a continuation-in-part of Application Serial No.
09/713,352, filed
November 10, 2000, which is a continuation-in-part of Application Serial No.
09/522,976,
filed March 10, 2000, which is a division of Application Serial No.
09/167,783, filed October
7, 1998, now Patent No. 6,083,594.
BACKGROUND OF THE INVENTION
The present invention relates to a fibrous insulation blanket pre-cut for
custom
fitting the fibrous insulation blanket into cavities of different widths
formed by the
framework of a building, such as both standard and non-standard width wall,
floor, ceiling
and roof cavities formed in part by successive frame members; and, in
particular, to a pre-
cut fibrous insulation blanket that can be handled as a unit when insulating a
cavity of a
certain predetermined width or easily separated or tom apart (by hand) along
one or more
cuts in the fibrous insulation blanket to form narrower fibrous insulation
blankets when
insulating a cavity having a lesser width.
Building structures, such as residential houses, 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, the ceilings below open
attic spaces, and
the roofs of such structures. The walls, ceilings, floors and roofs of these
structures
include framing members, e.g. studs, rafters, floor and ceiling joists, beams
and similar
support members, which are normally spaced-apart standard distances
established by the
building industry. Sheathing, paneling, lathing or similar construction
materials are
secured to these framing members to form the walls, ceilings, floors and roofs
of the
structures. While the contractor seeks to maintain the spacing of the framing
members in
these structures at these standard distances for ease of construction and the
insulation of
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the elongated cavities formed in these walls, ceilings, floors, and roofs,
frequently, the
walls, ceilings, floors and/or roofs of these structures include elongated
cavities defined, at
least in part, by successive or adjacent framing members which are spaced
apart a
nonstandard distance less than the standard spacing between framing members.
Studies
have shown that in a typical residential house, it is common for 50% or more
of the framing
members in the exterior walls of these structures to be spaced apart at
nonstandard
distances less than the standard spacing for such framing members.
When insulating these elongated cavities of various nonstandard widths, less
than
a standard width, it has been the practice to take an insulation batt
preformed to fit the
standard cavity width and reduce the width of the insulation batt by cutting
off and
removing a strip of insulation material from one or both longitudinal edges of
the insulation
batt. U.S. patent no. 5,331,787; issued July 26, 1994; to Kaarst; illustrates
this approach.
In the invention of this patent, the insulation batts or panels have widths at
least equal to a
predetermined maximum distance between adjacent support members defining the
cavities that the batts or panels are to insulate. The batts or panels are
provided with
facings that are folded over along the longitudinal edges of the batts or
panels so that
strips of insulation material can be cut away from one or both longitudinal
edges of the
batts or panels to fit the batts or panels between support members spaced
apart less than
the predetermined maximum spacing. This method of trimming the insulation
batts at the
job site by cutting the batts to fit between the more closely spaced support
members is
time consuming, raises a significant risk or safety issue, and relies heavily
on the worker's
skill to accurately trim the batt or panel.
U.S. patent no. 4,866,905; issued September 19, 1989; to Bihy et al; discloses
another approach to the problem. In the invention disclosed in this patent, a
continuous
strip of fibrous insulation with transverse marking lines is provided. The
worker cuts the
strip of fibrous insulation at the job site to a width somewhat greater than
the spacing
between the framing members, i.e. rafters, defining the space to be insulated.
Of course
this method of forming insulation batts or panels at the job site is also time
consuming and
relies heavily on the skill of the worker cutting the insulation strip to
achieve a good result.
A different approach to the problem is shown in U.S. patent no. 2,335,968;
issued
Dec. 7, 1943; to Sawtell. In the invention of this patent, the lateral edges
of the insulation
blanket are tumed down to enable the insulation batt to be placed between
framing
members, i.e. rafters, spaced doser together than the width of the insulation
batt. This
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approach does not require any cutting or trimming at the job site, but it can
be used only
where the spacing between the framing members is slightly less than the width
of
insulation blanket. In addition, the extra insulation material used to
insulate cavities having
less than a standard cavity width would add significantly to material costs.
Thus it can be seen that there has been a need to provide fibrous insulation
blankets or batts which can be used to either insulate cavities of a
predetermined width,
such as but not limited to standard width framework cavities, or be quickly
and easily
reduced in width to fit cavities of lesser widths, such as less than standard
width cavities
without a need to cut the fibrous insulation blankets at the job site with
knives or similar
cutting tools which is both time consuming and can result in cuts or other
injuries to the
workers.
SUMMARY OF THE INVENTION
The pre-cut fibrous insulation blanket or batt of U.S. Patent No. 6,083,594,
issued
July 4, 2000, provides a solution to the above discussed problems and the pre-
cut fibrous
insulation blanket or batt (hereinafter "blanket") of the present invention
provides another
improved solution to the above discussed problems. The pre-cut fibrous
insulation blanket
of the present invention is pre-cut for custom fitting the insulation blanket
into building
cavities of different widths formed by the framework of a building. The width
of the
insulation blanket is typically equal to or substantially equal to the width
of a standard
cavity to be insulated by the insulation blanket, e:g. about fourteen and one
half to about
fifteen inches or about twenty two and one half to about twenty three inches
for a standard
wall cavity. However, the pre-cut fibrous insulation blanket may also be
initially formed at a
selected width, such as but not limited to about thirteen to about thirteen
and one half
inches, less than a standard cavity width.
Do to the compressibility and resilience of the pre-cut fibrous insulation
blankets of
the present invention (generally pre-cut glass fiber insulation blankets), the
pre-cut fibrous
insulation blankets can be fitted into cavities having a width up to about one
and one half
inches less than the width of the pre-cut fibrous insulation blankets without
removing any
sections of the blankets, e.g. a pre-cut fibrous insulation blanket having a
width between
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about fourteen and one half to about fifteen inches can be installed within a
cavity having a
width of about thirteen inches or greater. For cavities of lesser widths,
greater than about
one and one half inches less in width than the pre-cut fibrous insulation
blankets, the pre-
cut fibrous insulation blankets may have one or more sections removed from the
blankets
so that the remaining portions of the pre-cut fibrous insulation blankets will
better fit into the
cavities being insulated.
The pre-cut fibrous insulation blanket of the present invention has one or
more
separable connectors within the blanket between and joining adjacent sections
of the
fibrous insulation blanket. The separable connectors are formed within the pre-
cut fibrous
insulation blanket by pairs of cuts in the major surfaces of the pre-cut
fibrous insulation
blanket. The cuts in each pair of cuts are spaced from each other a distance
sufficient to
form a separable connector within the pre-cut fibrous insulation blanket
between adjacent
sections of the pre-cut fibrous insulation blanket whereby the pre-cut fibrous
insulation
blanket can be handled as a unit for insulating a cavity having a
predetermined width, such
as but not limited to a standard cavity width, or easily separated or tom
apart by hand at
one or more of the separable connectors into two or more sections for
insulating a cavity
having a lesser width, such as a cavity having less than a standard cavity
width.
Since the separable connector(s) are formed within the pre-cut fibrous
insulation
blanket and, preferably about midway between the major surfaces of the pre-cut
fibrous
insulation blanket instead of adjacent a major surface of the fibrous
insulation blanket, as
in U.S. Patent No. 6,083,594, the pre-cut fibrous insulation blanket of the
present invention
may be easier to handle than the pre-cut fibrous insulation blankets of U.S.
Patent
6,083,594. The contact between the sidewalls of the cuts on either side of and
forming a
separable connector within the pre-cut fibrous insulation blanket of the
present invention
helps prevent the pre-cut fibrous insulation blanket from being flexed to much
at the
separable connector. With the single cut used to form the separable
connector(s) in U.S.
Patent No. 6,083,594, the contact between the sidewalls of the cut help
prevent the fibrous
insulation blanket from flexing to much at the separable connector when the
fibrous
insulation blanket is flexed in one direction, but allows the fibrous
insulation blanket to be
more easily flexed when flexed in the other direction with the separable
connector
functioning as a hinge adjacent one of the major surfaces of the fibrous
insulation blanket.
A major surface of the pre-cut fibrous insulation blanket may have a facing
bonded
thereto which, preferably, has one or more perforated lines or overlapping
tabs, tabs which
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are adhesively bonded together, and/or tear strings for permitting the facing
to be
separated at the cut(s) in that major surface of the pre-cut fibrous
insulation blanket to
facilitate the separation or tearing apart of the faced pre-cut fibrous
insulation blanket by
hand, if required. Preferably, the perforations of the perforated line(s) are
closed by the
bonding agent (typically, asphalt or another bituminous material or a pressure
sensitive
adhesive) bonding the facing to the pre-cut fibrous insulation blanket so that
the facing
functions as a vapor barrier in spite of the perforations. Thus, the pre-cut
fibrous insulation
blanket with the facing can still be quickly and easily modified to fit a
cavity of a particular
width without sacrificing the vapor barrier properties of the facing sheet.
Preferably, the facing sheet has tabs for securing the faced pre-cut fibrous
insulation blanket to framing members, e.g. with staples or an adhesive. These
tabs may
be located along each lateral edge of the pre-cut fibrous insulation blanket
and facing
sheet and pairs of tabs may be located adjacent each pair of cuts and
separable connector
in the pre-cut fibrous insulation blanket with perforated lines in the facing
sheet or an
adhesive layer separably joining the tabs of each pair of tabs.
With the pre-cut fibrous insulation blanket of the present invention, the
blanket can
be quickly and easily sized to fit wall or other building cavities without the
need to use
cutting tools at the job site to cut the insulation. Thus, the use of the pre-
cut fibrous
insulation blanket of the present invention to insulate the wall, floor,
ceiling and roof
cavities of buildings, especially wall cavities, not only reduces safety
concems, but greatly
speeds up the instaliation process. Since insulation installers are frequently
paid by the
piece, the present invention enables them to operate more profitably.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic elevation of the framework in an outside wall of a
building
with the pre-cut fibrous insulation blanket of the present invention installed
in standard
width and less than standard width wall cavities.
FIG. 2 is a schematic view of a major surface of an unfaced pre-cut fibrous
insulation blanket of the present invention with separable connectors, formed
by pairs of
aligned cuts, joining adjacent sections of the fibrous insulation blanket.
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FIG. 3 is a schematic end view of the unfaced pre-cut fibrous insulation
blanket of
FIG. 2.
FIG. 4 is a schematic view of a first major surface of a faced pre-cut fibrous
insulation blanket of the present invention with separable connectors, formed
by pairs of
aligned cuts, joining adjacent sections of the fibrous insulation blanket.
FIG. 5 is a schematic end view of the faced pre-cut fibrous insulation blanket
of
FIG. 4.
FIG. 6 is a schematic view of a faced, second major surface of the faced, pre-
cut
fibrous insulation blanket of FIG. 4.
FIG. 7 is a schematic transverse cross section through a faced pre-cut fibrous
insulation blanket of the present invention with integral tabs aligned or
substantially aligned
with each pair of cuts that form a separable connector between adjacent
sections of the
faced pre-cut fibrous insulation blanket and lateral tabs adjacent the lateral
edges of the
faced pre-cut fibrous insulation blanket.
FIG. 8 is a partial schematic transverse cross section through the faced pre-
cut
fibrous insulation blanket of FIG. 7 to better show the integral facing tabs
adjacent one of
the cuts in the fibrous insulation blanket forming a separable connector.
FIG. 9 is a partial schematic transverse cross section showing adjacent
sections
and integral facing tabs of the faced pre-cut fibrous insulation blanket of
FIG. 8 in the
process of being separated.
FIG. 10 is a partial schematic transverse cross section through a faced pre-
cut
fibrous insulation blanket of the present invention with the facing of FIGS. 7
to 9 and offset
and overlapping cuts forming a separable connector in the faced pre-cut
fibrous insulation
blanket.
FIG. 11 is a partial schematic transverse cross section through a faced pre-
cut
fibrous insulation blanket of the present invention with integral facing tabs
adjacent and
tucked into one of the cuts in the fibrous insulation blanket that form a
separable
connector.
FIG. 12 is a schematic transverse cross section through a faced pre-cut
fibrous
insulation blanket of the present invention with integral tabs aligned or
substantially aligned
with each pair of cuts that form a separable connector between adjacent
sections of the
faced pre-cut fibrous insulation blanket and lateral tabs adjacent the lateral
edges of the
faced pre-cut fibrous insulation blanket.
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FIG. 13 is a par6al schematic transverse cross section through the faced pre-
cut
fibrous insulation blanket of FIG. 12 to better show the integral facing tabs
adjacent one of
the cuts in the fibrous insulation blanket forming a separable connector.
FIG. 14 is a partial schematic transverse cross section through a faced pre-
cut
fibrous insulation blanket of the present invention with the facing of FIGS.
12 and 13 and
offset and overlapping cuts forming a separable connector in the faced pre-cut
fibrous
insulation blanket.
FIG. 15 is a partial schematic transverse cross section through a faced pre-
cut
fibrous insulation blanket of the present invention with a facing similar to
that of the
embodiment of FIGS. 12 and 13 except that the tabs are formed from a sheet
other than
the facing sheet.
FIG. 16 is a schematic transverse cross section through a faced pre-cut
fibrous
insulation blanket of the present invention with integral tabs aligned or
substantially aligned
with each pair of cuts that form a separable connector between adjacent
sections of the
faced pre-cut fibrous insulation blanket and lateral tabs adjacent the lateral
edges of the
faced pre-cut fibrous insulation blanket.
FIG. 17 is a partial schematic transverse cross section through the faced pre-
cut
fibrous insulation blanket of FIG. 17 to better show the integral facing tabs
adjacent one of
the cuts in the fibrous insulation blanket forming a separable connector.
FIG. 18 is a partial schematic transverse cross section through a faced pre-
cut
fibrous insulation blanket of the present invention with the facing of FIGS.
16 and 17 and
offset and overlapping cuts forming the separable connector in the faced pre-
cut fibrous
insulation blanket.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a portion of a typical outside wall of a residential house with
the pre-
cut fibrous insulation blanket 20 of the present invention installed in both
standard width
and non-standard width wall cavities of the outside wall. The widths of the
wall cavities are
defined by the framing members 22 (e.g. 2X4, 2X6 or 2X10 wall studs) which are
spaced
apart a standard distance (e.g. spaced apart on sixteen or twenty four inch
centers) for
standard cavities 24 and less than the standard distance for non-standard
width cavities
26.
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While the faced and unfaced pre-cut fibrous insulation blankets of the present
invention may be made of other fibrous materials, preferably the faced and
unfaced pre-
cut fibrous insulation blankets of the present invention are made of glass
fibers and
typically have a density between about o.4 pounds/ft3 and about 1.5
pounds/ft3. Examples
of other fibers that may be used to form the unfaced and faced pre-cut fibrous
insulation
blankets of the present invention are mineral fibers, such as but not limited
to, rock wool
fibers, slag fibers, and basalt fibers, and organic fibers such as but not
limited to
polypropylene, polyester and other polymeric fibers. The fibers in the unfaced
and faced
pre-cut fibrous insulation blankets of the present invention may be bonded
together for
increased integrity, e.g. by a binder at their points of intersection such as
but not limited to
urea phenol formaldehyde or other suitable bonding materials, or the unfaced
and faced
pre-cut fibrous insulation blankets of the present invention may be binderless
provided the
blankets possess the required integrity.
Preferably, the faced and unfaced pre-cut fibrous insulation blankets of the
present
invention are resilient so that, after being * compressed to insert the pre-
cut fibrous
insulation blanket or section(s) of the pre-cut fibrous insulation blanket
into a cavity having
a width somewhat less than the width of the pre-cut fibrous insulation blanket
or the
section(s) of the pre-cut fibrous insulation blanket being inserted into the
cavity, the pre-cut
fibrous insulation blanket or one or more sections of the pre-cut fibrous
insulation blanket
inserted into the cavity will expand to the width of a cavity and press
against the sides of
the cavity to hold or help hold the insulation blanket in place.
Typically, for most applications, such as walls in residential buildings, the
resilient,
unfaced or faced pre-cut fibrous insulation blankets of the present invention
are delivered
to the installer in the form of batts about forty six to about forty eight
inches or about ninety
three inches long or in the form of rolls of various lengths greater than
ninety three inches
in length. Typically, the widths of the faced and unfaced pre-cut fibrous
insulation blankets
of the present invention are substantially equal to or equal to the standard
cavity width to
be insulated with the pre-cut fibrous insulation blanket, e.g. about fourteen
and one half to
about fifteen inches wide for a cavity where the standard center to center
spacing of the
wall, floor, ceiling or roof framing members is sixteen inches (the cavity has
a width of
about fourteen and one half inches) and about twenty two and one half to about
twenty
three inches wide for a cavity where the standard center to center spacing of
the wall, floor,
ceiling or roof framing members is twenty four inches (the cavity has a width
of about
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twenty two and one half inches). However, for certain applications, the faced
or unfaced
pre-cut fibrous insulation blanket may have a different initial width, such as
but not limited
to about thirteen to about thirteen and one half inches.
The following examples illustrate how the faced or unfaced pre-cut fibrous
insulation blanket of the present invention may be formed into sections. For a
faced or
unfaced pre-cut fibrous insulation blanket having a width of about fifteen
inches which is
divided into three sections, the sections may be about three and one-half,
about five, and
about six and one-half inches wide (from right to left or left to right). For
a faced or
unfaced pre-cut fibrous insulation blanket having a width of about fifteen
inches which is
divided into four sections, preferably, the sections are about two and one
half, about four,
about four, and about four and one half inches wide (from left to right or
right to left).
Another example of section widths for a pre-cut fibrous insulation blanket
about fifteen
inches wide is about three and one-half, about four and one-half, about five
and one-half,
and about one and one-half inches wide (from right to left or left to right).
For a faced or
unfaced pre-cut fibrous insulation blanket having a width of about twenty
three inches
which is divided into four sections, preferably, the sections are about eleven
and one half,
about four, about four, and about three and one half inches wide (from left to
right or right
to left). For a faced or unfaced pre-cut fibrous insulation blanket having a
width of about
twenty three inches which is divided into six sections, preferably, the
sections are about
three, about four, about four, about three, about four and about five inches
wide (from left
to right or right to left). For a faced or unfaced pre-cut fibrous insulation
blanket about
thirteen inches in width which is divided into three sections, the sections
may be about
three, about four and one half and about five and one half inches wide.
Note that the preferred slit configurations for the fifteen inch and twenty
three inch
wide pre-cut fibrous insulation blankets are designed to provide blanket
pieces in widths
that for the most part differ in roughly two inch increments. For example with
the preferred
2 1/2 inch, 4 inch, 4 inch and 4 1/2 inch wide section configuration of a
fifteen inch wide
pre-cut fibrous insulation blanket, with one tear of the unfaced or faced pre-
cut fibrous
insulation blanket, a blanket 2 1/2 inches, 4 1/2 inches, 6 1/2 inches, 8 1/2
inches, 10 1/2
inches or 12 1/2 inches in width can be formed to fit a cavity of a particular
width less than
a standard cavity width. For example with the preferred 3 inch, 4 inch, 4
inch, 3 inch, 4
inch, and 5 inch wide section configuration of a twenty three inch wide pre-
cut fibrous
insulation blanket, with one tear of the unfaced or faced pre-cut fibrous
insulation blanket,
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a blanket 3 inches, 5 inches, 7 inches, 9 inches, 11 inches, 12 inches, 14
inches, 15
inches, 18 inches, or 20 inches in width can be formed to fit a cavity of a
particular width
less than a standard cavity width. Insulation installers generally custom cut
insulation
blankets to be about 1 inch to about 1 1/2 inches wider than the cavity being
insulated and
the blanket widths formed above essentially permit cavities of all widths to
be insulated
with a piece of insulation blanket about 1/2 of an inch to about 2 inches
wider than the
cavity being insulated without over compressing the insulation in the
direction of its width.
In both the fifteen inch and twenty three inch wide pre-cut fibrous insulation
blankets, the
ability to form blanket pieces which generally differ in width in about two
inch increments
was accomplished. by making the two outer most sections two inches different
in width and
then making the inner sections, except for one of the central sections of the
twenty three
inch wide blanket about four inches in width.
The thicknesses of the face or unfaced pre-cut fibrous insulation blankets of
the
present invention are determined by the amount of thermal resistance or sound
control
desired and the depth of the cavities being insulated. Typically, the pre-cut
fibrous
insulation blanket is about three to about ten inches or more in thickness and
approximates the depth of the cavity being insulated. For example, in a wall
cavity defined
in part by nominally 2X4 or 2X6 inch studs or framing members, the pre-cut
fibrous
insulation blankets will have thicknesses of about three and one half inches
and about five
and one quarter inches respectively.
FIGS. 2 and 3 show an unfaced embodiment 20 of the pre-cut fibrous insulation
blanket of the present invention. The pre-cut fibrous insulation blanket 20
has a length "L",
a width 'W" and a thickness 'T'. A first major surface 30 and a second major
surface 32
of the pre-cut fibrous insulation blanket 20 are each defined by the width "W"
and length
"L" of the insulation blanket. There are one or more pairs of cuts, preferably
two, three or
more pairs of cuts (two pairs of cuts, 34 and 36, are shown) in the first and
second major
surfaces 30 and 32 of the pre-cut fibrous insulation blanket 20 which divide
the pre-cut
fibrous insulation blanket 20 into two or more sections and, preferably,
three, four or more
sections (three sections, 38, 40 and 42, are shown) extending the length of
the pre-cut
fibrous insulation blanket.
The cuts forming each pair of cuts 34 and 36 in the pre-cut fibrous insulation
blanket 20: extend for the length of the pre-cut fibrous insulation blanket;
extend
perpendicular to or substantially perpendicular to the major surfaces 30 and
32 of the pre-
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cut fibrous insulation blanket; are aligned with or substantially aligned with
each other, and
are spaced from each other (terminate short of contacting each other) to form
separable
connectors 44 and 46 within the pre-cut fibrous insulation blanket 20 which
join the
adjacent sections 38, 40 and 42 of the pre-cut fibrous insulation blanket
together. With
this structure, the pre-cut fibrous insulation blanket 20 can be handled as a
unit for
insulating a cavity 24 having a predetermined width, such as but not limited
to a thirteen
inch width or a fourteen and one half or twenty two and one half inch standard
cavity width,
or easily separated or tom apart by hand at one or more of the separable
connectors 44
and 46 formed by the pairs of cuts 34 and/or 36 (separated without the need to
use of a
knife or other cutting tool) for insulating a cavity 26 having a lesser width,
such as less than
a standard cavity width. While the separable connectors 44 and 46 can be
located within
but close to one of the major surfaces of the pre-cut fibrous insulation
blanket 20,
preferably, the separable connectors 44 and 46 are located in a midportion of
the pre-cut
fibrous insulation blanket and, more preferable, centered between the major
surfaces 30
and 32 of the pre-cut fibrous insulation blanket. Preferably, the cuts forming
each pair of
cuts 34 and 36 extend from the first and second major surfaces 30 and 32 of
the pre-cut
fibrous insulation blanket 20 to within about one half to about one-eighth of
an inch of each
other and, more preferably, to within about one quarter to about three
sixteenths of an inch
of each other so that the separable connectors 44 and 46 can be easily
separated or tom
apart by hand, if desired. The heights or thicknesses of the separable
connector(s) 44 and
46 can vary with the integrity of the pre-cut fibrous insulation blanket 20
with the
connector(s) being greater in height or thicker for insulation blankets with
less integrity.
The width of the cuts forming the separable connectors, such as the cuts 34
and 36 in the
pre-cut fibrous insulation blanket 20, in faced or unfaced embodiments of the
pre-cut
fibrous insulation blanket of the present invention is typically less than one
hundredth of an
inch and the resilience of the pre-cut fibrous insulation blankets of the
present invention
causes the cuts in the pre-cut fibrous insulation blankets of the present
invention to close
after the cuts are made in the blanket.
FIGS. 4 to 18 show nine different embodiments 120 to 920 of the faced pre-cut
fibrous insulation blanket of the present invention. Preferably, the facings
or facing sheets
of the faced pre-cut fibrous insulation blankets 120 to 920 are made of kraft
paper, a foil-
scrim-kraft paper laminate, or a polymeric film, such as but not limited to
polyethylene, and
are bonded to a major surface of the pre-cut fibrous insulation blanket by a
bonding agent.
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Preferably, the bonding agent for kraft paper or foil-scrim-kraft paper
facings is an asphalt
or other bituminous material that can be coated onto or otherwise applied to
one side of
the facing sheet just prior to applying the facing sheet to the pre-cut
fibrous insulation
blanket and the bonding agent for the polymeric film facing is a commercially
available
pressure sensitive adhesive that can be coated onto or otherwise applied to
one side of the
facing sheet just prior to applying the facing sheet to the pre-cut fibrous
insulation blanket.
FIGS. 4-6 show a faced embodiment 120 of the pre-cut fibrous insulation
blanket.
As shown, the pre-cut fibrous insulation blanket 120 of FIGS. 4-6 has a first
major surface
130 and a second major surface 132. There are one or more pairs of cuts,
preferably two,
three or more pairs of cuts (two pairs of cuts, 134 and 136, are shown) in the
first and
second major surfaces 130 and 132 of the pre-cut fibrous insulation blanket
which divide
the pre-cut fibrous insulation blanket 120 into two or more sections,
preferably three, four
or more sections (three sections, 138, 140 and 142, are shown) extending the
length of the
pre-cut fibrous insulation blanket. The faced pre-cut fibrous insulation
blanket 120 is the
same as the unfaced embodiment 20 with the-following exceptions: the faced
embodiment
120 of the pre-cut fibrous insulation blanket includes a facing 150 with
lateral tabs 160 for
securing the faced pre-cut fibrous insulation blanket to framing members by
stapling or
other conventional means and a bonding agent 152 which bonds the facing 150 to
the
second major surface 132 of the faced pre-cut fibrous insulation blanket.
The cuts forming each pair of cuts 134 and 136 in the faced pre-cut fibrous
insulation blanket 120: extend for the length of the faced pre-cut fibrous
insulation blanket
120; extend perpendicular to or substantially perpendicular to the major
surfaces 130 and
132 of the faced pre-cut fibrous insulation blanket; are aligned with or
substantially aligned
with each other; and are spaced from each other (terminate short of contacting
each other)
to form separable connectors 144 and 146 within the faced pre-cut fibrous
insulation
blanket which join the adjacent sections 138, 140 and 142 of the faced pre-cut
fibrous
insulation blanket together as a unit for handling.
While the separable connectors 144 and 146 can be located within but close to
one
of the major surface of the faced pre-cut fibrous insulation blanket 120,
preferably, the
separable connectors 144 and 146 are located in a midportion of the faced pre-
cut fibrous
insulation blanket and, more preferable, centered between the major surfaces
130 and 132
of the faced pre-cut fibrous insulation blanket. Preferably, the cuts forming
each pair of
cuts 134 and 136 in the faced pre-cut fibrous insulation blanket extend from
the first and
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CA 02361795 2001-11-09
second major surfaces 130 and 132 of the faced pre-cut fibrous insulation
blanket 120 to
within about one half to about one eighth of an inch of each other and, more
preferably, to
within about one quarter to about three sixteenths of an inch of each other so
that the
separable connectors can be easily separated or tom apart by hand, if desired.
The
heights or thicknesses of the separable connector(s) 144 and 146 can vary with
the
integrity of the faced pre-cut fibrous insulation blanket 120 with the
connector(s) being
greater in height or thicker for insulation blankets with less integrity.
The facing or facing sheet 150 typically overlies the entire second major
surface
132 of the pre-cut fibrous insulation blanket 120 and is bonded to the second
major
surface of the pre-cut fibrous insulation blanket by the bonding agent 152. As
shown, the
facing sheet 150 has first and second perforated lines 154 and 156 therein
extending for
the length of the faced pre-cut fibrous insulation blanket. The perforated
lines 154 and 156
are aligned or substantially aligned longitudinally with the pairs of cuts 134
and 136 in the
first and second major surfaces of the faced pre-cut fibrous insulation
blanket 120. With
this structure, the faced pre-cut fibrous insulation blanket 120, with the
facing 150, can be
handled as a unit for insulating a cavity having a predetermined with, such as
but not
limited to a thirteen inch width or a fourteen and one half or a twenty two
and one half
standard cavity width, or easily separated by hand into sections 138, 140
and/or 142 by
separating or tearing apart the blanket at the first or second separable
connector 144 or
146 and the facing sheet at the first or second perforated line 154 or 156
(separated
without the need to use of a knife or other cutting tool) for insulating a
cavity having a
lesser width, such as less than a standard cavity width.
The spaced apart perforations of the perforated lines 154 and 156 may be of
various shapes, including but not limited to, round, oval, elongated, slit
shaped, etc. and
the spacing between the perforations and the length of the perforations may
vary as long
as the facing is easily separated by hand along the line formed by the
perforations.
Preferably, the perforations of the first and second perforated lines 154 and
156 in the
embodiment shown, are filled, e.g with the bonding agent 152 that bonds the
facing sheet
150 to the second major surface 132 of the pre-cut fibrous insulation blanket
120 or a
similar material, to close the perforations so that the facing sheet 150
functions as a vapor
barrier. While perforations are preferred, tear strings could be used with or
substituted for
the perforated lines 154 and 156. The tear strings would have a free end for
gripping; be
bonded to the facing by the bonding agent 152; and would extend along lines
that coincide
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CA 02361795 2001-11-09
with the locations of the perforated lines 154 and 156.
FIGS. 7, 8 and 9 show a second embodiment 220 of the faced pre-cut fibrous
insulation blanket of the present invention. As shown, the faced pre-cut
fibrous insulation
blanket 220 has a first major surface 230 and a second major surface 232.
There are one
or more pairs of cuts, preferably two, three or more pairs of cuts (cuts 234,
236 and 238
are shown) in the first and second major surfaces 230 and 232 of the pre-cut
fibrous
insulation blanket which divide the pre-cut fibrous insulation blanket 220
into two or more
sections, preferably three, four or more sections (four sections 240, 242, 244
and 246 are
shown) extending the length of the pre-cut fibrous insulation blanket.
The cuts forming each pair of cuts 234, 236 and 238 in the faced pre-cut
fibrous
insulation blanket 220: extend for the length of the pre-cut fibrous
insulation blanket;
extend perpendicular to or substantially perpendicular to the major surfaces
230 and 232
of the faced pre-cut fibrous insulation blanket; are aligned with or
substantially aligned with
each other; and are spaced from each other (terminate short of contacting each
other) to
form separable connectors 248, 250 and 252 within the pre-cut fibrous
insulation blanket
220 which join the adjacent sections 240, 242, 244 and 246 of the faced pre-
cut fibrous
insulation blanket together for handling, but which can be easily separated or
tom apart by
hand. While the separable connectors 248, 250 and 252 can be located within
but close
to one of the major surfaces of the faced pre-cut fibrous insulation blanket
220, preferably,
the separable connectors 248, 250 and 252 are located in a midportion of the
faced pre-
cut fibrous insulation blanket and, more preferable, centered between the
major surfaces
230 and 232 of the faced pre-cut fibrous insulation blanket. Preferably, the
cuts of each
pair of cuts 234, 236 and 238 extend from the first and second major surfaces
230 and
232 of the faced pre-cut fibrous insulation blanket 220 to within about one
half to about
one-eighth of an inch of each other and, more preferably, to within about one
quarter to
about three sixteenths of an inch of each other to form separable connectors
which can be
easily separated or torn apart by hand. The heights or thicknesses of the
separable
connector(s) 248, 250 and 252 can vary with the integrity of the pre-cut
fibrous insulation
blanket 220 with the connector(s) being greater in height or thicker for
insulation blankets
with less integrity.
The facing or facing sheet 254 typically overlies the entire second major
surface
232 of the pre-cut fibrous insulation blanket 220 and is bonded to the second
major
surface of the pre-cut fibrous insulation blanket 220 by a bonding agent 256.
As shown in
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CA 02361795 2001-11-09
FIG. 7, the facing sheet 254 has lateral tabs 258 and pairs of tabs 260, 262
and 264
aligned or substantially aligned with the pairs of cuts 234, 236 and 238 and
the separable
connectors 248, 250 and 252 in the faced pre-cut fibrous insulation blanket
220 for stapling
or otherwise securing the faced pre-cut fibrous insulation blanket or
section(s) of the faced
pre-cut fibrous insulation blanket to frame members. The lateral tabs 258,
which may be
formed by Z-shaped pleats in the facing 254 as shown in FIG. 7, extend for the
length of
the faced pre-cut fibrous insulation blanket 220. The pairs of tabs 260, 262
and 264 also
extend for the lengths of the cuts 234, 236 and 238 and the separable
connectors 248,
250 and 252 of the faced pre-cut fibrous insulation blanket 220. Each pair of
tabs 260,
262 and 264 is formed by double folding the facing sheet back upon itself to
form a Z-
shaped pleat in the facing sheet 254 with the tabs of each pair of tabs 260,
262 and 264
being separably connected to each other by perforated lines 266, 268 and 270
at a fold of
the Z-shaped pleat so that the facing sheet 254 can be separated at each of
the pairs of
cuts and separable connectors. With this structure, the faced pre-cut fibrous
insulation
blanket 220 with the facing 254, can be handled as a unit for insulating a
cavity having a
predetermined width, such as but not limited to a thirteen inch width or a
standard cavity
width of fourteen and one half or twenty two and one half inches, or easily
separated or
torn apart by hand into blanket sections 240, 242, 244 and/or 246 by
separating or tearing
apart the faced pre-cut fibrous insulation blanket 220 at the pair of cuts 234
and the
separable connector 248 in the blanket and the perforated line 266 of the
facing sheet 254,
the pair of cuts 236 and the separable connector 250 in the blanket and the
perforated line
268 of the facing sheet 254, or the pair of cuts 238 and separable connector
252 in the
blanket and the perforated line 270 of the facing sheet 254 (separated without
the need to
use of a knife or other cutting tool) for insulating a cavity having a lesser
width, e.g. less
than a standard cavity width.
The spaced apart perforations of the perforated lines 266, 268 and 270 may be
of
various shapes, including but not limited to, round, oval, elongated, slit
shaped, etc. and
the spacing between perforations and the length of the perforations may vary
as long as
the facing is easily separated by hand along the line formed by the
perforations.
Preferably, the perforations of perforated lines 266, 268 and 270, are filled,
e.g. with the
bonding agent 256 that bonds the facing sheet 254 to the second major surface
232 of the
pre-cut fibrous insulation blanket or a similar material, to close the
perforations so that the
facing sheet 254, functions as a vapor barrier. While perforations are
preferred, tear
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CA 02361795 2001-11-09
strings could be used with or substituted for the perforated lines 266, 268
and 270. The
tear strings would have a free end for gripping; be bonded to the facing by
the bonding
agent 256; and would extend along lines that coincide with the locations of
the perforated
lines 266, 268 and 270.
The use of pairs of tabs 260, 262 and 264 formed by Z-shaped pleats in the
facing
254 wherein the tabs of each pair of tabs are separably bonded together by the
bonding
agent 256 bonding the facing 254 to the second major surface of the faced pre-
cut fibrous
insulation blanket 220 provides several advantages: the overlapping and
bonding together
of the tabs across their widths in each pair of tabs with the perforations at
the juncture of
the tabs improves the vapor barrier properties of the perforated facing; there
is less
tendency for the facing 254 to split during installation because the bonding
agent 256
joining the tabs of each pair of tabs together can yield when the faced pre-
cut fibrous
insulation blanket is flexed; the folds at the perforations in the Z-shaped
pleats facilitate the
tearing of the facing 254 at the perforations and help prevent the tears from
propagating
out of the tabs; and, as shown in FIG. 9, as the blanket sections adjacent a
pair of tabs are
separated, the tabs which initially lie on a major surface of the blanket are
pulled away
from the major surface of the blanket to extend generally perpendicular to the
major
surface of the blanket for better grasping by a worker as the tabs peel away
from each
other and finally separate from each other along the perforated lines. In
addition, the use
of facing tabs adjacent each pair of cuts and separable oonnectors between
blanket
sections, in this and other faced embodiments of the invention, not only
provides tabs for
securing the blanket sections in place, but also enables the facings to
provide vapor
barriers across the entire widths of blanket sections even when the means of
separating
the facings along each pair of cuts and separable connectors, e.g. perforated
lines, are not
properly aligned with each pair of cuts and separable connectors.
The integral pairs of tabs 260, 262 and 264 aligned with or substantially
aligned
with the cuts 234, 236 and 238 and separable connectors 248, 250 and 252 of
the faced
pre-cut fibrous insulation blanket 220 plus lateral tabs, such as the lateral
tabs 258 shown
in FIG. 7, can be used to secure the sections 240, 242, 244 and 246 of the
faced pre-cut
fibrous insulation blanket 220 to framing members, by stapling or other
conventional
means, either as a unit or as one or more sections when one or more sections
240, 242,
244 and 246 are separated from the remainder of the faced pre-cut fibrous
insulation
blanket. Preferably, the tabs are about one half to about one and one half
inches in width.
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CA 02361795 2001-11-09
When securing the faced pre-cut fibrous insulation blanket 220 or one or more
sections
240, 242, 244 and 246 of the pre-cut fibrous insulation blanket to framing
members, the
pairs tabs 260, 262 and 264 and lateral tabs 258 used to secure the blanket
are at least
partially unfolded and extended outward from the faced pre-cut fibrous
insulation blanket
220 or sections 240, 242, 244 and/or 246 of the faced pre-cut fibrous
insulation blanket
prior to stapling or otherwise securing the tabs to the framing members.
FIG. 10 is a partial transverse cross section of a third embodiment 320 of the
faced
pre-cut fibrous insulation blanket of the present invention showing the pair
of cuts 334 in
the first and second major surfaces 330 and 332 of the faced pre-cut fibrous
insulation
blanket forming the separable connector 348 between sections 340 and 342 of
the faced
pre-cut fibrous insulation blanket. With one exception, the faced pre-cut
fibrous insulation
blanket 320 is the same as the faced pre-cut fibrous insulation blanket 220.
Unlike the
faced pre-cut fibrous insulation blanket 220 wherein the cuts of each pair of
cuts forming
the separable connectors are aligned or substantially aligned with each other,
the cuts of
the pairs of cuts forming the separable connectors of the faced pre-cut
fibrous insulation
blanket 320 are laterally offset with respect to each other and, preferably,
overlap to form
the separable connectors. As shown in FIG. 10, the cuts of the pair of cuts
334 are
laterally offset with respect to each other and overlap a distance "OL" to
form the
separable connector 348.
Having the cuts forming the pairs of cuts in the faced pre-cut fibrous
insulation
blanket offset and overlapping with respect to each other, may make the
embodiment of
FIG. 10 easier to produce. By offsetting and overlapping the cuts forming the
separable
connectors, the tolerances for the distance to be maintained between the cuts
to form the
separable connectors may be easier to maintain. The offsetting and overlapping
of the
cuts forming the separable connectors of the faced pre-cut fibrous insulation
blanket 320
may also facilitate the separation of the faced pre-cut fibrous insulation
blanket at the
separable connectors. The fibers of the fibrous blankets typically used in the
invention, i.e.
glass fiber blankets, are typically randomly oriented with respect to each
other but, due to
the manner in which the fibers are collected to form a blanket, the fibers
tend to lie
predominately in layers or planes generally parallel to the major surfaces of
the blanket.
Thus, the blankets tend to separate more easily along these layers.
The facing sheet 354 is bonded to the second major surface 332 of the faced
pre-
cut fibrous insulation blanket by a bonding agent 356, such as asphalt or
another
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CA 02361795 2001-11-09
bituminous material or a pressure sensitive adhesive. As shown in FIG. 10, the
facing 354
is provided with a pair of integral, tabs 360 aligned or substantially aligned
with the pair of
cuts 234 and the separable connector 348 and extending for the length of the
cuts 234 and
the separable connector 348. The pair of tabs 360 is formed by double folding
the facing
sheet 354 back upon itself to form a Z-shaped pleat in the facing sheet 354
with the tabs of
the pair of tabs 360 being separably connected to each other by a perforated
lines 366 so
that the facing can be separated at the pair of cuts 234 and separable
connector 348. An
identical pair of integral tabs is aligned with or substantially aligned with
and extends for
the length of each of the other pairs of cuts and separable connectors of the
faced pre-cut
fibrous insulation blanket 320 joining other sections of the faced pre-cut
fibrous insulation
blanket 320. With this structure, the faced pre-cut fibrous insulation blanket
320 with the
facing 354, can be handled as a unit for insulating a cavity having a
predetermined width,
such as but not limited to a thirteen inch width or a standard cavity width of
fourteen and
one half or twenty two and one half inches, or easily separated or torn apart
by hand into
one or more blanket sections by separating' or tearing apart the faced pre-cut
fibrous
insulation blanket 320 at a pair of cuts and separable connector in the
blanket and at a
perforated line of the facing sheet 354 joining adjacent tabs (separated
without the need to
use of a knife or other cutting tool) for insulating a cavity having a lesser
width, e.g. less
than a standard cavity width. Preferably, the perforations of the perforated
lines separably
joining the tabs are filled, e.g. with the bonding agent 356 or a similar
material so that the
facing 354 functions as a vapor barrier and, as discussed above, while
perforations are
preferred, tear strings could be used with or substituted for the perforated
lines to effect
tab separation.
The pairs of tabs aligned with or substantially aligned with the pairs of cuts
and the
separable connectors plus lateral tabs, such as the lateral tabs of the pre-
cut fibrous
insulation blanket 220 shown in FIG. 7, can be used to secure the sections of
the faced
pre-cut fibrous insulation blanket 320 to framing members by stapling or other
conventional
means either as a unit or as one or more sections when one or more sections
are
separated from the remainder of the pre-cut fibrous insulation blanket. As
with the
embodiment of FIGS. 7 to 9, when securing the faced pre-cut fibrous insulation
blanket
320 or one or more sections of the faced pre-cut fibrous insulation blanket
320 to framing
members, the tabs adjacent the separable connectors and the lateral tabs used
to secure
the blanket are at least partially unfolded and extended outward from the pre-
cut fibrous
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CA 02361795 2001-11-09
insulation blanket 320 and/or sections of the pre-cut fibrous insulation
blanket prior to
stapling or othenniise securing the tabs to the framing members. Where a
facing is not
desired, an unfaced pre-cut fibrous insulation blanket can be used with offset
and,
preferably, overlapping pairs of cuts forming the separable connectors. Except
for the lack
of a facing, such a pre-cut fibrous insulation blanket would be the same as
the faced pre-
cut fibrous insulation blanket 320.
FIG. 11 is a partial transverse cross section of a fourth embodiment 420 of
the
faced pre-cut fibrous insulation blanket of the present invention showing a
pair of cuts 434
in the first and second major surfaces 430 and 432 of the faced pre-cut
fibrous insulation
blanket forming a,separable connector 448 between sections 440 and 442 of the
faced
pre-cut fibrous insulation blanket. The facing sheet 454 is bonded to the
second major
surface 432 of the faced pre-cut fibrous insulation blanket by the bonding
agent 456 which
preferably is' an asphalt or other bituminous material or a pressure sensitive
adhesive.
Except for the use of pairs of tabs inserted into the cuts in the second major
surface of the faced pre-cut fibrous insulation blanket 420, the faced pre-cut
fibrous
insulation blanket 420 is the same as the faced pre-cut fibrous insulation
blanket 220 of
FIGS. 7 to 9. As shown in FIG. 11, the facing sheet 454 is provided with a
pair of tabs 460
adjacent and extending for the length of the cut 434 in the second major
surface 432 of the
faced pre-cut fibrous insulation blanket 420. The tabs of the pair of tabs 460
are joined
together along a perforated line 466 so that the tabs can be separated from
each other at
the connector 448 when the sections 440 and 442 are separated from each other
and, as
shown in FIG. 11, the pair of tabs 460 is tucked down into the cut 434. An
identical pair of
tabs are provided adjacent any additional cuts in the second major surface 432
of the
faced pre-cut fibrous insulation blanket forming additional separable
connectors joining
other sections of the faced pre-cut fibrous insulation blanket 420. With this
structure, the
faced pre-cut fibrous insulation blanket 420 with the facing 454, can be
handled as a unit
for insulating a cavity having a predetermined width, such as but not limited
to a thirteen
inch width or a standard cavity width of fourteen and one half or twenty two
and one half
inches, or easily separated or tom apart by hand into one or more blanket
sections by
separating or tearing apart the faced pre-cut fibrous insulation blanket 420
at a pair of cuts
and separable connector in the blanket and at a perforated line of the facing
sheet 454
joining the adjacent tabs (separated without the need to use of a knife or
other cutting tool)
for insulating a cavity having a lesser width, e.g. less than a standard
cavity width.
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CA 02361795 2001-11-09
The tabs inserted into the cuts in the second major surface of the faced pre-
cut
fibrous insulation blanket plus lateral tabs, such as the tabs 258 of the
faced pre-cut
fibrous insulation blanket shown in FIG. 7, can be used to secure the sections
of the faced
pre-cut fibrous insulation blanket 420 to framing members by stapling or other
conventional
means either as a unit or as one or more sections when one or more sections
are
separated from the remainder of the faced pre-cut fibrous insulation blanket.
As with the
faced pre-cut fibrous insulation blanket 220 , when securing the faced pre-cut
fibrous
insulation blanket 420 or one or more sections of the faced pre-cut fibrous
insulation
blanket 420 to framing members, the tabs adjacent the cuts in the second major
surface
forming the connectors and the lateral tabs used to secure the blanket are at
least partially
unfolded and extended outward from the faced pre-cut fibrous insulation
blanket 420
and/or sections of the faced pre-cut fibrous insulation blanket prior to
stapling or otherwise
securing the tabs to.the framing members.
FIGS. 12 and 13 show a fifth embodiment 520 of the faced pre-cut fibrous
insulation blanket of the present invention. As shown, the faced pre-cut
fibrous insulation
blanket 520 has a first major surface 530 and a second major surface 532.
There are one
or more pairs of cuts, preferably two, three or more pairs of cuts (cuts 534,
536 and 538
are shown) in the first and second major surfaces 530 and 532 of the pre-cut
fibrous
insulation blanket which divide the pre-cut fibrous insulation blanket 520
into two or more
sections, preferably three, four or more sections (four sections 540, 542, 544
and 546 are
shown) extending the length of the pre-cut fibrous insulation blanket.
The cuts forming each pair of cuts 534, 536 and 538 in the faced pre-cut
fibrous
insulation blanket 520: extend for the length of the pre-cut fibrous
insulation blanket;
extend perpendicular to or substantially perpendicular to the major surfaces
530 and 532
of the faced pre-cut fibrous insulation blanket; are aligned with or
substantially aligned with
each other; and are spaced from each other (terminate short of contacting each
other) to
form separable connectors 548, 550 and 552 within the pre-cut fibrous
insulation blanket
520 which join the adjacent sections 540, 542, 544 and 546 of the faced pre-
cut fibrous
insulation blanket together for handling, but which can be easily separated or
tom apart by
hand. While the separable connectors 548, 550 and 552 can be located within
but close
to one of the major surfaces of the faced pre-cut fibrous insulation blanket
520, preferably,
the separable connectors 548, 550 and 552 are located in a midportion of the
faced pre-
cut fibrous insulation blanket and, more preferable, centered between the
major surfaces
-20-
CA 02361795 2001-11-09
530 and 532 of the faced pre-cut fibrous insulation blanket. Preferably, the
cuts of each
pair of cuts 534, 536 and 538 extend from the first and second major surfaces
530 and
532 of the faced pre-cut fibrous insulation blanket 520 to within about one
half to about
one-eighth of an inch of each other and, more preferably, to within about one
quarter to
about three sixteenths of an inch of each other to form separable connectors
which can be
easily separated or torn apart by hand. The heights or thicknesses of the
separable
connector(s) 548, 550 and 552 can vary with the integrity of the pre-cut
fibrous insulation
blanket 520 with the connector(s) being greater in height or thicker for
insulation blankets
with less integrity.
The facing, or facing sheet 554 typically overlies the entire second major
surface
532 of the pre-cut fibrous insulation blanket 520 and is bonded to the second
major
surface of the pre-cut fibrous insulation blanket 520 by a bonding agent 556.
As shown in
FIG. 12, the facing sheet 554 has lateral tabs 558 and pairs of tabs 560, 562
and 564
aligned or substantially aligned with the pairs of cuts 534, 536 and 538 and
the separable
connectors 548, 550 and 552 in the faced pre-cut fibrous insulation blanket
520 for stapling
or otherwise securing the faced pre-cut fibrous insulation blanket or
section(s) of the faced
pre-cut fibrous insulation blanket to frame members. The lateral tabs 558,
which may be
formed by Z-shaped pleats in the facing 554 as shown in FIG. 12, extend for
the length of
the faced pre-cut fibrous insulation blanket 520. The pairs of tabs 560, 562
and 564 also
extend for the length of the faced pre-cut fibrous insulation blanket 520.
Each tab of the
pairs of tabs 560, 562 and 564 is formed by double folding the facing sheet
back upon
itself to form a Z-shaped pleat in the facing sheet 554 with the tabs of each
pair of tabs
560, 562 and 564 being separably connected to each other by perforated lines
566, 568
and 570 that extend for the length of the tabs. The perforated lines,
separably joining the
tabs of each pair of tabs 560, 562 and 564 are aligned or substantially
aligned
longitudinally with the pairs of cuts 534, 536 and 538 and the separable
connectors 548,
550 and 552, respectively, so that the facing sheet can be separated at each
pair of cuts
and separable connector in the blanket. With this structure, the faced pre-cut
fibrous
insulation blanket 520 with the facing 554, can be handled as a unit for
insulating a cavity
having a predetermined width, such as but not limited to a thirteen inch width
or a standard
cavity width of fourteen and one half or twenty two and one half inches, or
easily separated
or tom apart by hand into blanket sections 540, 542, 544 and/or 546 by
separating or
tearing apart the faced pre-cut fibrous insulation blanket 520 at the pair of
cuts 534 and the
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CA 02361795 2001-11-09
separable connector 548 in the blanket and the perforated line 566 of the
facing sheet 554,
the pair of cuts 536 and the separable connector 550 in the blanket and the
perforated line
568 of the facing sheet 554, or the pair of cuts 538 and separable connector
552 in the
blanket and the perforated line 570 of the facing sheet 554 (separated without
the need to
use of a knife or other cutting tool) for insulating a cavity having a lesser
width, e.g. less
than a standard cavity width.
The spaced apart perforations of the perforated lines 566, 568 and 570 may be
of
various shapes, including but not limited to, round, oval, elongated, slit
shaped, etc. and
the spacing between perforations and the length of the perforations may vary
as long as
the facing is easily separated by hand along the line formed by the
perforations.
Preferably, the perforations of perforated lines 566, 568 and 570, are filled,
e.g. with the
bonding agent 556 that bonds the facing sheet 554 to the second major surface
532 of the
pre-cut. fibrous insulation blanket or a similar material, to close the
perforations so that the
facing sheet 554 functions as a vapor barrier. While perforations are
preferred, tear
strings could be used with or substituted for the perforated lines 566, 568
and 570. The
tear strings would have a free end for gripping; be bonded to the facing by
the bonding
agent 556; and would extend along lines that coincide with the locations of
the perforated
lines 566, 568 and 570.
The integral pairs of tabs 560, 562 and 564 aligned with or substantially
aligned
with the cuts 534, 536 and 538 and separable connectors 548, 550 and 552 of
the faced
pre-cut fibrous insulation blanket 520 plus lateral tabs, such as the lateral
tabs 558 shown
in FIG. 12, can be used to secure the sections 540, 542, 544 and 546 of the
faced pre-cut
fibrous insulation blanket 520 to framing members, by stapling or other
conventional
means, either as a unit or as one or more sections when one or more sections
540, 542,
544 and 546 are separated from the remainder of the faced pre-cut fibrous
insulation
blanket. Preferably, the tabs are about one half to about one and one half
inches in width.
When securing the faced pre-cut fibrous insulation blanket 520 or one or more
sections
540, 542, 544 and 546 of the pre-cut fibrous insulation blanket to framing
members, the
pairs tabs 560, 562 and 564 and lateral tabs 558 used to secure the blanket
are at least
partially unfolded and extended outward from the faced pre-cut fibrous
insulation blanket
520 or sections 540, 542, 544 and/or 546 of the faced pre-cut fibrous
insulation blanket
prior to stapling or otherwise securing the tabs to the framing members.
FIG. 14 is,a partial transverse cross section of a sixth embodiment 620 of the
faced
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CA 02361795 2001-11-09
pre-cut fibrous insulation blanket of the present invention showing the pair
of cuts 634 in
the first and second major surfaces 630 and 632 of the faced pre-cut fibrous
insulation
blanket forming the separable connector 648 between sections 640 and 642 of
the faced
pre-cut fibrous insulation blanket. With one exception, the faced pre-cut
fibrous insulation
blanket 620 is the same as the faced pre-cut fibrous insulation blanket 520.
Unlike the
faced pre-cut fibrous insulation blanket 520 wherein the cuts of each pair of
cuts forming
the separable connectors are aligned or substantially aligned with each other,
the cuts of
the pairs of cuts forming the separable connectors of the faced pre-cut
fibrous insulation
blanket 620 are laterally offset with respect to each other and overlap to
form the
separable connectors. As shown in FIG. 14, the cuts of the pair of cuts 634
are laterally
offset with respect to each other and, preferably, overlap a distance "OL" to
form the
separable connector 648.
The facing sheet 654 is bonded to the second major surface 632 of the faced
pre-
cut fibrous insulation blanket by a bonding agent 656, such as asphalt or
another
bituminous material or a pressure sensitive adhesive. As shown in FIG. 14, the
facing 654
is provided with a pair of integral, tabs 660 aligned or substantially aligned
with the pair of
cuts 634 and the separable connector 648 and extending for the length of the
pre-cut
fibrous insulation blanket 620. The each tab of the pair of tabs 660 is formed
by double
folding the facing sheet 654 back upon itself to form a Z-shaped pleat in the
facing sheet
654 with the tabs of the pair of tabs 660 being separably connected to each
other by a
perforated lines 666. The perforated line 666, separably joining the tabs 660
is aligned or
substantially aligned longitudinally with the pairs of cuts 634 and the
separable connector
648 so that the facing can be separated at the pair of cuts 634 and separable
connector
648. An identical pair of integral tabs is aligned with or substantially
aligned with and
extends for the length of each of the other pairs of cuts and separable
connectors of the
faced pre-cut fibrous insulation blanket 620 joining other sections of the
faced pre-cut
fibrous insulation blanket 620. With this structure, the faced pre-cut fibrous
insulation
blanket 620 with the facing 654, can be handled as a unit for insulating a
cavity having a
predetermined width, such as but not limited to a thirteen inch width or a
standard cavity
width of fourteen and one half or twenty two and one half inches, or easily
separated or
tom apart by hand into one or more blanket sections by separating or tearing
apart the
faced pre-cut fibrous insulation blanket 620 at a pair of cuts and separable
connector in the
blanket and at a perforated line of the facing sheet 654 joining adjacent tabs
(separated
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CA 02361795 2001-11-09
without the need to use of a knife or other cutting tool) for insulating a
cavity having a
lesser width, e.g. less than a standard cavity width. Preferably, the
perforations of the
perforated lines separably joining the tabs are filled, e.g. with the bonding
agent 656 or a
similar material so that the facing 654 functions as a vapor barrier and, as
discussed
above, while perforations are preferred, tear strings could be used with or
substituted for
the perforated lines used to effect the separation of the tabs.
The pairs of tabs aligned with or substantially aligned with the pairs of cuts
and the
separable connectors plus lateral tabs, such as the lateral tabs of the pre-
cut fibrous
insulation blanket 520 shown in FIG. 12, can be used to secure the sections of
the faced
pre-cut fibrous insulation blanket 620 to framing members by stapling or other
conventional
means either as a unit or as one or more sections when one or more sections
are
separated from the remainder of the pre-cut fibrous insulation blanket. As
with the
embodiment of FIGS. 12 and 13, when securing the faced pre-cut fibrous
insulation
blanket 620 or one or more sections of the faced pre-cut fibrous insulation
blanket 620 to
framing members, the tabs adjacent the separable connectors and the lateral
tabs used to
secure the blanket are at least partially unfolded and extended outward from
the pre-cut
fibrous insulation blanket 620 and/or sections of the pre-cut fibrous
insulation blanket prior
to stapling or otherwise securing the tabs to the framing members. FIG. 15 is
a partial
transverse cross section of a seventh embodiment 720 of the faced pre-cut
fibrous
insulation blanket of the present invention showing the pair of cuts 734 in
the first and
second major surfaces 730 and 732 of the faced pre-cut fibrous insulation
blanket forming
the separable connector 748 between sections 740 and 742 of the faced pre-cut
fibrous
insulation blanket. With one exception, the faced pre-cut fibrous insulation
blanket 720 is
the same as the faced pre-cut fibrous insulation blanket 520. Unlike the faced
pre-cut
fibrous insulation blanket 520 where the tabs adjacent the cuts in the second
major surface
of blanket are integral with the facing sheet, the tabs of the faced pre-cut
fibrous insulation
blanket 720 are formed by separate sheets of facing material bonded to the
facing sheet
754.
The facing sheet 754 is bonded to the second major surface 732 of the pre-cut
fibrous insulation blanket by the bonding agent 756 and is either cut or
provided a
perforated line 766 aligned with the cut 734 in the second major surface 732
of the pre-cut
fibrous insulation blanket. A pair of Z-shaped tabs 760 are also provided
adjacent and
extending for the length of the cut 734 in the second major surface 732 of the
pre-cut
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fibrous insulation blanket. The pair of tabs 760 are formed by a separate
sheet 772 that is
bonded to the facing sheet 754 on either side of the cut 734 by a bonding
agent 774. The
pair of tabs 760 are joined together along a perforated line 776 so that the
tabs can be
separated from each other when the sections 740 and 742 are separated from
each other
and, as shown in FIG. 15, each Z-shaped tab 760 is formed by twice folding the
sheet 772
back upon itself into a pleat. Preferably, the sheet 772, like the facing
sheet 754, is made
of kraft paper, a foil-scrim-kraft paper laminate, or a polymeric film, such
as but not limited
to polyethylene. An identical pair of tabs is aligned with or substantially
aligned with and
extends for the length of each of the other pairs of cuts and separable
connectors of the
faced pre-cut fibrous insulation blanket 720 joining other sections of the
faced pre-cut
fibrous insulation blanket 720. With this structure, the faced pre-cut fibrous
insulation
blanket 720 with the facing 754, can be handled as a unit for insulating a
cavity having a
predetermined width, such as but not limited to a thirteen inch width or a
standard cavity
width of fourteen and one half or twenty two and one half inches, or easily
separated or
tom apart by hand into one or more blanket- sections by separating or tearing
apart the
faced pre-cut fibrous insulation blanket 720 at a pair of cuts and separable
connector in the
blanket and at perforated lines of the facing sheet 754 joining adjacent tabs
(separated
without the need to use of a knife or other cutting tool) for insulating a
cavity having a
lesser width, e.g. less than a standard cavity width. Preferably, the
perforations of the
perforated lines separably joining the tabs are filled, e.g. with the bonding
agent 756 or a
similar material so that the facing 754 functions as a vapor barrier.
The pairs of tabs aligned with or substantially aligned with the pairs of cuts
and the
separable connectors plus lateral tabs, such as the lateral tabs of the pre-
cut fibrous
insulation blanket 520 shown in FIG. 12, can be used to secure the sections of
the faced
pre-cut fibrous insulation blanket 720 to framing members by stapling or other
conventional
means either as a unit or as one or more sections when one or more sections
are
separated from the remainder of the pre-cut fibrous insulation blanket. As
with the
embodiment of FIGS. 12 and 13, when securing the faced pre-cut fibrous
insulation
blanket 720 or one or more sections of the faced pre-cut fibrous insulation
blanket 720 to
framing members, the tabs adjacent the separable connectors and the lateral
tabs used to
secure the blanket are at least partially unfolded and extended outward from
the pre-cut
fibrous insulation blanket 720 and/or sections of the pre-cut fibrous
insulation blanket prior
to stapling or otherwise securing the tabs to the framing members.
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CA 02361795 2001-11-09
FIGS. 16 and 17 show an eighth embodiment 820 of the faced pre-cut fibrous
insulation blanket of the present invention. As shown, the faced pre-cut
fibrous insulation
blanket 820 has a first major surface 830 and a second major surface 832.
There are one
or more pairs of cuts, preferably two, three or more pairs of cuts (cuts 834,
836 and 838
are shown) in the first and second major surfaces 830 and 832 of the pre-cut
fibrous
insulation blanket which divide the pre-cut fibrous insulation blanket 820
into two or more
sections, preferably three, four or more sections (four sections 840, 842, 844
and 846 are
shown) extending the length of the pre-cut fibrous insulation blanket.
The cuts forming each pair of cuts 834, 836 and 838 in the faced pre-cut
fibrous
insulation blanket 820: extend for the length of the pre-cut fibrous
insulation blanket;
extend perpendicular to or substantially perpendicular to the major surfaces
830 and 832
of the faced pre-cut fibrous insulation blanket; are aligned with or
substantially aligned with
each other, and are spaced from each other (terminate short of contacting each
other) to
form separable connectors 848, 850 and 852 within the pre-cut fibrous
insulation blanket
820 which join the adjacent sections 840, 842, 844 and 846 of the faced pre-
cut fibrous
insulation blanket together for handling, but which can be easily separated or
torn apart by
hand. While the separable connectors 848, 850 and 852 can be located within
but close
to one of the major surfaces of the faced pre-cut fibrous insulation blanket
820, preferably,
the separable connectors 848, 850 and 852 are located in a midportion of the
faced pre-
cut fibrous insulation blanket and, more preferable, centered between the
major surfaces
830 and 832 of the faced pre-cut fibrous insulation blanket. Preferably, the
cuts of each
pair of cuts 834, 836 and 838 extend from the first and second major surfaces
830 and
832 of the faced pre-cut fibrous insulation blanket 820 to within about one
half to about
one-eighth of an inch of each other and, more preferably, to within about one
quarter to
about three sixteenths of an inch of each other to form separable connectors
which can be
easily separated or tom apart by hand. The heights or thicknesses of the
separable
connector(s) 848, 850 and 852 can vary with the integrity of the pre-cut
fibrous insulation
blanket 820 with the connector(s) being greater in height or thicker for
insulation blankets
with less integrity.
The facing 854 of the pre-cut fibrous insulation blanket 820 is made of a
plurality or
series of sheets 855 which overlap successive sheets forming the facing 854.
The facing
or facing sheet 854, formed by the series of overlapping sheets 855, typically
overlies the
entire second major surface 832 of the faced pre-cut fibrous insulation
blanket 820 and is
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CA 02361795 2001-11-09
bonded to the second major surface of the faced pre-cut fibrous insulation
blanket 820 by
a bonding agent 856. As shown in FIG. 16, the facing sheet 854 has lateral
tabs 858 and
pairs of tabs 860 and 861, 862 and 863, and 864 and 865, adjacent each of the
cuts 834,
836 and 838 in the second major surface 832 of the faced pre-cut fibrous
insulation
blanket 820 for stapling or otherwise securing the faced pre-cut fibrous
insulation blanket
or section(s) of the faced pre-cut fibrous insulation blanket to frame
members. The lateral
tabs 858 extend for the length of the faced pre-cut fibrous insulation blanket
820. The
pairs of tabs 860 and 861, 862 and 863, and 864 and 865 are aligned or
substantially
aligned longitudinally with and extend for the lengths of the pairs of cuts
834, 836 and 838
and the separable connectors 848, 850 and 852 of the faced pre-cut fibrous
insulation
blanket 820. Each pair of tabs 860 and 861, 862 and 863, and 864 and 865 is
formed by a
lateral edge portion of a preceding sheet 855 overlapping a lateral edge
portion of a
succeeding sheet 855 at one of the cuts 834, 836 and 838 in the second major
surface of
the blanket with both lateral portions of the sheets extending laterally
beyond the cut in
opposite directions as shown in FIGS. 16 and 17. The tabs 860 and 861, 862 and
863,
and 864 and 865 of each pair of tabs are separably bonded together by the
bonding agent
856 or a similar adhesive so that the facing can be separated at each of the
cuts and
separable connectors. With this structure, the faced pre-cut fibrous
insulation blanket 820
with the facing 854, can be handled as a unit for insulating a cavity having a
predetermined
width, such as but not limited to a thirteen inch width or a standard cavity
width of fourteen
and one half or twenty two and one half inches, or easily separated or tom
apart by hand
into blanket sections 840, 842, 844 and/or 846 by separating or tearing apart
the faced
pre-cut fibrous insulation blanket 820 at the pair of cuts 834 and separable
connector 848
in the blanket and the tabs 860 and 861 of the facing sheet 854, the pair of
cuts 836 and
separable connector 850 in the blanket and the pair of tabs 862 and 863 of the
facing
sheet 854, or the pair of cuts 838 and separable connector 852 in the blanket
and the pair
of tabs 864 and 865 of the facing sheet 854 (separated without the need to use
of a knife
or other cutting tool) for insulating a cavity having a lesser width, e.g.
less than a standard
cavity width.
Preferably, the lateral edge portions of the sheets 855 forming the facing
sheet 854
are bonded together e.g. with the bonding agent 856 that bonds the facing
sheet 854 to
the second major surface 832 of the pre-cut fibrous insulation blanket or a
similar material,
so that the facing sheet 854 functions as a vapor barrier. The pairs of tabs
860 and 861,
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CA 02361795 2001-11-09
862 and 863, and 864 and 865 adjacent the cuts 834, 836 and 838 in the second
major
surface of the faced pre-cut fibrous insulation blanket plus lateral tabs,
such as the lateral
tabs 858 shown in FIG. 16, can be used to secure the sections 840, 842, 844
and 846 of
the faced pre-cut fibrous insulation blanket 820 to framing members, by
stapling or other
conventional means, either as a unit or as one or more sections when one or
more
sections 840, 842, 844 and 846 are separated from the remainder of the faced
pre-cut
fibrous insulation blanket. Preferably, each tab is about one half of an inch
to about one
and one half inches wide. When securing the faced pre-cut fibrous insulation
blanket 820
or one or more sections 840, 842, 844 and 846 of the pre-cut fibrous
insulation blanket to
framing members,;the pairs tabs 860 and 861, 862 and 863, and 864 and 865, and
lateral
tabs 858 used to secure the blanket are extended outward from the faced pre-
cut fibrous
insulation blanket 820 or sections 840, 842, 844 and/or 846 of the faced pre-
cut fibrous
insulation blanket prior to stapling or otherwise securing the tabs to the
framing members.
FIG. 18 is a partial transverse cross section of a ninth embodiment 920 of the
faced pre-cut fibrous insulation blanket of the present invention showing the
pair of cuts
934 in the first and second major surfaces 930 and 932 of the faced pre-cut
fibrous
insulation blanket forming the separable connector 948 between sections 940
and 942 of
the faced pre-cut fibrous insulation blanket. With one exception, the faced
pre-cut fibrous
insulation blanket 920 is the same as the faced pre-cut fibrous insulation
blanket 820.
Unlike the faced pre-cut fibrous insulation blanket 820 wherein the cuts of
each pair of cuts
forming the separable connectors are aligned or substantially aligned with
each other, the
cuts of the pairs of cuts forming the separable connectors of the faced pre-
cut fibrous
insulation blanket 920 are laterally offset with respect to each other and,
preferably,
overlap to form the separable connectors. As shown in FIG. 18, the cuts of the
pair of cuts
934 are laterally offset with respect to each other and overlap a distance
"OL" to form the
separable connector 948.
The pair of tabs 960 and 961 are aligned or substantially aligned
longitudinally with
and extend for the lengths of the pair of cuts 934 and the separable connector
948 of the
faced pre-cut fibrous insulation blanket 920. The pair of tabs 960 and 961 is
formed by a
lateral edge portion of a preceding sheet 955 overlapping a lateral edge
portion of a
succeeding sheet 955 at the cut 934 in the second major surface of the blanket
with both
lateral portions of the sheets extending laterally beyond the cut in opposite
directions as
shown in FIG. 18. The tabs 960 and 961 are separably bonded together by the
bonding
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CA 02361795 2001-11-09
agent 956 or a similar adhesive so that the facing can be separated at each of
the cuts
and separable connectors. Identical pairs of tabs are provided adjacent and
extending for
the length of any additional cuts in the second major surface of the faced pre-
cut fibrous
insulation blanket forming separable connectors joining other sections of the
faced pre-cut
fibrous insulation blanket 920. With this structure, the faced pre-cut fibrous
insulation
blanket 920 with the facing 954, can be handled as a unit for insulating a
cavity having a
predetermined width, such as but not limited to a thirteen inch width or a
standard cavity
width of fourteen and one half or twenty two and one half inches, or easily
separated or
torn apart by hand into one or more blanket sections by separating or tearing
apart the
faced pre-cut fibrous insulation blanket 920 at a pair of cuts and separable
connector in the
blanket, at a pair of tabs of the facing sheet 954 (separated without the need
to use of a
knife or other cutting tool) for insulating a cavity having a lesser width,
e.g. less than a
standard cavity width.
The tabs adjacent the cuts in the second major surface of the pairs of cuts
forming
the separable connectors plus lateral tabs, such as the tabs of the faced pre-
cut fibrous
insulation blanket shown in FIG. 16, can be used to secure the sections of the
faced pre-
cut fibrous insulation blanket 920 to framing members by stapling or other
conventional
means either as a unit or as one or more sections when one or more sections
are
separated from the remainder of the pre-cut fibrous insulation blanket. As
with the
embodiment of FIGS. 16 and 17, when securing the faced pre-cut fibrous
insulation
blanket 920 or one or more sections of the faced pre-cut fibrous insulation
blanket to
framing members, the tabs adjacent the separable connectors and the lateral
tabs used to
secure the blanket are extended outward from the faced pre-cut fibrous
insulation blanket
920 and/or sections of the faced pre-cut fibrous insulation blanket prior to
stapling or
otherwise securing the tabs to the framing members.
As an example of the versatility of the faced and unfaced pre-cut fibrous
insulation
blankets 20 to 920, the preferred different widths of the sections, when three
sections are
formed in a fifteen inch wide embodiment of the invention, enable the pre-cut
fibrous
insulation blankets 20 to 920 to be quickly and easily formed into widths of
about three and
one-half inches (e.g. section 38), five inches (e.g. section 40), six and one-
half inches (e.g.
section 42), eight and one-half inches ( e.g. sections 38 and 40) and eleven
and one-half
inches (e.g. sections 40 and 42). Where the pre-cut fibrous insulation blanket
is separated
into four sections, the installer has even more options. Thus, the pre-cut
fibrous insulation
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CA 02361795 2001-11-09
blankets 20 to 920 can not only be used to insulate cavities having standard
widths, but the
width of the pre-cut fibrous insulation blanket can also be quickly and easily
modified to fit
cavities of various non-standard widths. The use of a resilient fibrous
insulation blanket 20
to 920, such as a resilient glass fiber insulation blanket, further enhances
the ability of the
pre-cut fibrous insulation blanket to conform to various cavity widths.
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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