Note: Descriptions are shown in the official language in which they were submitted.
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KIT OF PARTS FOR BAND JOIST INSULATION AND METHOD OF MANUFACTURE
FIELD OF THE INVENTION
[0001] The invention relates to insulation products for insulating between
framing
members of a building.
BACKGROUND
[0002] With reference to Fig. 1, a basement or crawl space of a building has
an
exterior foundation wall (100) for the most part below grade level of the
earth. The top of the
wall (100) is covered with a sill or sill plate (102) of wood or other plate
material. Sometimes
the sill plate is omitted. A frame for supporting a floor is constructed, as
follows. Framing
members of the building known as joist plates or headers (104) are sawn lumber
or boards,
which are laid edgewise to span along, either the top of the sill plate (102),
or the top of the
basement wall (100) in the absence of a sill plate (102). Horizontal framing
members of the
building comprise joists (106) that span from one joist plate (104) to
another. The joists (106)
can be dimensional lumber, such as, 2x10 wood, or composite wood joists, such
as 9.5 inch I-
joists, or open web joists, such as, 9.5" open web joists, or steel I-beams of
various depths
and flanges, or other materials and similar shapes that function to support
the floor (108) and
a floor load. Further, the joists (106) and/or the headers (104) can be
fabricated from, one or
more, elemental metals, alloys, polymer materials, material composites, and
laminates, and
combinations thereof.
[0003] Ends of the joists (106) are nailed or otherwise secured to the headers
(104),
and the headers (104) are toe nailed or otherwise secured to the sill plate
(102) In high wind
regions, metal anchor plates, not shown, secure the joists (106) and the
headers (104) to the
sill plate (102). The joists (106) include an exterior joist (106a) in
reference to an endmost
joist (106a) that is located at the exterior of the building. An exterior
joist (106a) includes,
and is not limited to, one that is parallel to the joists (106) of the floor
framing. Each floor
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(108) of a building can be supported on a similar construction of joists (106)
and headers
(104).
[0005] Exterior joists (106a) and exterior joist plates or headers (104)
extend along an
exterior of the building. Collectively, they are referred to as band joists.
The band joists are
required to be filled by insulation installed on site. The insulation is
installed in a band joist
cavity defined with a width between two joists (106) on centers, and further
defined with a
length between a floor (108) or subfloor supported by the joists (106), and
the plate (102)
supporting the joists (106). The plate (106) can be supported by a basement
wall (100), the
thickness of which basement wall (100) defines the depth of the band joist
cavity.
[0006] The joists (106), for example, are sawn lumber or boards of standard 2x
(two-
by) thickness. The actual thickness is 1.5 inches. The joists (106) are spaced
apart on
standard centers, or centerlines, of 12 inches, 16 inches, 19.2 inches or 24
inches. Thus the
width of the band joist cavity between joists on 12 inch centers is 10.5
inches wide. The
width of the band joist cavity between joists on 16 inch centers is 14.5
inches wide. The
width of the band joist cavity between joists on 19.2 inch centers is 17.7
inches wide. The
width of the band joist cavity between joists on 24 inch centers is 22.5
inches wide.
[0007] The joists (106) are 2x12's , measuring 1.5 inches thick by 11.5 inches
wide.
Thus, 2x12 joists (106) define band joist cavities 11.5 inches in length.
Alternatively, the
joists (106) are 2x10's, measuring 1.5 inches thick by 9.5 inches wide. Thus,
2x10 joists
(106) define band joist cavities 9.5 inches in length. The joists (106) and
the headers (104)
are the same board size. Alternatively, the length of a band joist cavity is
13.5 inches defined
by the width of 2x14 joists (106). Alternatively, the length of a band joist
cavity is 15.5
inches defined by the width of 2x16 joists (106).
[0008] Fibrous insulation is available as a commercial product in widths of
11, 15,
15.25, 16, 23, 23.25, 24 or 25 inches, although, 25 inches is not a common
insulation width.
The insulation is supplied as a continuous roll or as a batt having a length,
including 46, 47,
93, 94, 96 or 105 inches. Insulation of 11 inches wide is capable of
insulating the band joist
cavity of 10.5 inches wide between two joists (106) on 12 inch centers. The
insulation of 11
inches wide adapts by compression, i.e., compression to a smaller volume, to
fit in the space
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10.5 inches wide. However, prior to the invention, the insulation was measured
and cut to
length at the installation site
[0009] Similarly, insulation of 15, 15.25 or 16 inches wide adapts by
compression to
fill the band joist cavity of 14.5 inches wide between 2x (two-by) joists
(106) on 16 inch
centers. However, prior to the invention, the insulation was measured and cut
to length at the
installation site. Insulation of 23, 23.25, 24 or 25 inches wide adapts by
compression to fill
the band joist cavity of either 17.7 inches wide or 22.5 inches wide between
joists (106) on
19.2 inch centers or 24 inch centers. However, prior to the invention, the
insulation was
measured and cut to length at the installation site.
[0010] Prior to the invention, the batt or continuous roll was measured and
cut for
each band joist cavity. Usually, an oversize piece was measured and cut. An
oversize piece
was assured to become compressed in both width and length in the cavity to be
retained in
place. Further, an oversize piece was cut to avoid having an undersized piece
that would be
too small, and therefore discarded as scrap. However, if the oversize piece
was too generous
in size, when the oversize piece could have been smaller, then some amount of
insulation was
wasted. Further, after cutting and removing too generous an oversize piece
from a batt or roll,
the remainder of the batt or roll would become too short for further use, and
therefore would
be discarded as scrap. Thus, there is a need for an invention that reduces the
time expended
for measuring and cutting insulation into pieces. Further, there is a need for
an invention that
avoids cutting a piece that is either too small or too generous in size.
[0011] Further, scrap is produced when a batt or roll of insulation is split
lengthwise
so as to have a narrow and long piece to cover an area that is narrow and
long. For example, a
narrow and long piece of insulation would be needed to cover along the length
of a band joist
(106a), Fig. 1 B, at an exterior of a building. Thus, there is a need for an
invention that would
reduce scrap and lost time resulting from having to measure and split a batt
or roll to have a
narrow and long piece at an installation site for insulating along a length of
a band joist
(106a).
SUMMARY OF THE INVENTION
[0012] According to the invention, insulation capable of compression is precut
into
batts, and the batts are partially divided into segments, for filling band
joist cavities with a
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whole number of the segments between spaced apart joists. An advantage of the
invention
resides in an insulation product having insulation segments with a set of
fixed dimensions to
insulate band joist cavities of different widths and lengths, as defined by
joists of different
widths and spaced apart on different centers. Another advantage of the
invention is that the
segments are precut to reduce scrap that would result from cutting the batt
into segments that
are either too small or too generous in size. A further advantage of the
invention is that
installation time is saved by reducing the time for measuring and cutting the
insulation to
desired sizes.
[0013] By installing the segments in different orientations, the segments
adapt by
compression to fill band joist cavities of different widths and lengths.
Measuring and cutting
the insulation is no longer necessary, and after removing one or more of the
segments, the
remainder of the batt has one or more segments, which have useful widths and
lengths,
thereby avoiding a potential source of scrap.
[0014] According to another embodiment of the invention, the segments are
partially
divided from one another, and advantageously remain connected in a batt or in
a more
lengthy folded batt until they are separated at the point of use or
installation.
[0015] According to another embodiment of the invention, a batt of insulation
capable of compression is precut into segments of said insulation having a
desired R-value
and thickness, and further having a set of fixed dimensions, such that a whole
number of said
segments fills a band joist cavity.
[0016] According to an embodiment of the invention, the segments of insulation
have
widths and lengths, such that a whole segment adapts to cover the width of a
band joist cavity
between two joists, and a whole number of segments are oriented and installed
beside another
to fill a band joist cavity between two joists on relatively wide centers. The
segments are
installed in the same orientation or in different orientations to adapt to
band joist cavities of
different widths and lengths.
[0017] Another embodiment of the invention pertains to a method of making
presently manufactured insulation having different widths, into segments of
insulation having
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a set of fixed dimensions that fill band joist cavities of different widths
and lengths with a
whole number of segments.
[0018] According to a further embodiment of the invention, a kit of parts has
multiple
batts of insulation precut into segments, each having a desired R-value and
thickness, and
further having a set of fixed dimensions for insulating band joist cavities of
different widths
and lengths.
[0019] According to a further embodiment of the invention, a kit of parts has
one or
more batts of insulation precut into segments, and a length of narrow width
insulation to
insulate along an exterior joist.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. IA is an isometric view of a portion of a floor joist construction
disclosing an insulation covered band joist cavity.
[0021] FIG. 1 B is a view similar to Fig. 1 A disclosing an insulation covered
exterior
joist.
[0022] FIG. 2A is an isometric view of a batt of at least four insulation
segments
long.
[0023] FIG. 2B is an isometric view of one batt one segment wide, or two batts
one
segment wide, made from a continuous length of insulation, and each of the
batts being at
least three segments in length.
[0024] FIG. 2C is an isometric view of a kit of parts.
[0025] FIG. 2D is a schematic view of a rotary die cutting cylinder.
[0026] FIG. 2E is a schematic view of another embodiment of a rotary die
cutting
cylinder.
[0027] FIG. 3 is an isometric view of a narrow length, folded batt,
insulation.
[0028] FIG. 4 is an isometric view of another embodiment of a kit of parts.
[0029] FIG. 5 is an isometric view of a segmented batt having a segmented
vapor
retarder.
DETAILED DESCRIPTION
[0030] This description of the exemplary embodiments is intended to be read in
connection with the accompanying drawings, which are to be considered part of
the entire
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written description. In the description, relative terms such as "lower,"
"upper," "horizontal,"
"vertical,", "above," "below," "up," "down," "top" and "bottom" as well as
derivative thereof
(e.g., "horizontally," "downwardly," "upwardly," etc.) should be construed to
refer to the
orientation as then described or as shown in the drawing under discussion.
These relative
terms are for convenience of description and do not require that the apparatus
be constructed
or operated in a particular orientation. Terms concerning attachments,
coupling and the like,
such as "connected" and "interconnected," refer to a relationship wherein
structures are
secured or attached to one another either directly or indirectly through
intervening structures,
as well as both movable or rigid attachments or relationships, unless
expressly described
otherwise.
[0031] With reference to Fig. 2A, an embodiment of the invention pertains to a
batt
(200) of insulation capable of compression. In Fig. 2A, the batt (200) has a
desired batt length
of four segments (200a) long and is one segment (200a) wide. Alternatively, a
lengthy batt
(200) is made longer than four segments (200a) long, and then is folded, i.e.
doubled back on
itself, at each interval of a desired batt length, or at each interval of four
segments (200a)
long.
[0032] Fig. 2A discloses four segments (200a) each oriented with their longer
dimension across the width of the batt (200), and their shorter dimension
extending
lengthwise of the batt (200). Fig. 2B discloses two sets of three segments
(200a), each being
oriented ninety degrees with respect to the four segments (200a) in the batt
(200) of Fig. 2A.
Thus with reference to Fig. 2B, another embodiment of the batt (200) has a
desired batt
length of three segments (200a) long, and is one segment (200a) wide.
Alternatively, a
lengthy batt (200) is made longer than three segments long, and then is
folded, i.e. doubled
back on itself, at each interval of a desired batt length, or at each interval
of three segments
(200a) long.
[0033] Alternatively, Fig 2B discloses a continuous length (200b) of
insulation
partially divided lengthwise by a penetrating cut (200d) to provide a batt
(200) of two
segments (200a) wide. The batt (200) of two segments wide is partially divided
by
penetrating cuts (200c) into three segments (200a) long. For example, the batt
width is two
segments (200a) wide, with two segments (220a) having the same width or
different widths.
Alternatively, completely dividing the continuous length (200b) of insulation
by a continuous
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lengthwise cut (200d), provides two individual batts (200) of one segment
(200a) wide.
Alternatively, a continuous length (200b) of insulation can be divided
lengthwise, either
partially or completely, as described by Fig. 2B, and further made into batts
(200) of four
segments (200a) long according to a batt (200) as disclosed by Fig. 2A.
[0034] Each batt (200) disclosed by either of Figs. 2A and 2B is partially
divided
lengthwise into segments (200a). The segments (200a) and the batt (200) are
manufactured
by severing or cutting a continuous length (200b) of insulation. For example,
each of the
segments (200a) is manufactured by penetrating a guillotine type chopping
blade into the
thickness of the continuous length (200b) of insulation. The chopping blade
cuts a cut (200c)
or groove having a width equal to the width of the chopping blade. Further,
the cut (200c)
extends only partially through the batt (200), such that the segments (200a)
are only partially
severed or partially divided from one another, and are only partially severed
or partially
divided from the batt (200). They are prevented from separation from the batt
(200) to avoid
being damaged or lost. For example, the cut (200c) can sever the batt (200)
leaving an un-
severed portion of about .05 to 0.5 inches, and more preferably, less than
0.25 inches in
thickness or depth. Alternatively, the batt (200) can be skip chopped, meaning
chopped by a
chopping blade having open grooves in a cutting edge to make a series of
interruptions, such
that, the chopping blade makes a cut having a series of interruptions along
the length of the
cut, i.e. a cut in the form of a series of perforations.
[0035] When cutting the batt (200) to a desired batt length, a guillotine
chopping
blade may be used that severs completely across the continuous insulation
(200b) to form a
batt (200) of any desired number of segments (200a). When a lengthy batt (200)
is longer
than the four segments (200a), as in Fig. 2A, the lengthy batt (200) is folded
at each interval
of four segments (200a). When a lengthy batt (200) is longer than the three
segments (200a),
as in Fig. 2B, the lengthy batt (200) is folded at each interval of three
segments (200a).
[0036] Figs. 2D and 2E disclose embodiments of a preferred rotary die cutting
cylinder (210) for cutting the continuous insulation (200b) into batts (200)
and segments
(200a). The rotary die cutting cylinder (210) is part of a rotary die cutting
system of the type
manufactured by CORfine of Dayton, Ohio. The rotary die cutting cylinder (210)
has slicing
rules (212) or perfing rules (212) for making corresponding cuts (200c)
between the
insulation segments (200a). A slicing rule (212) is a rule that cuts a
continuous cut (200c) that
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penetrates only part way through the thickness of the insulation (200b). A
perfing rule (212)
will make a perforated cut (200c) that has a series of interruptions, such
that the insulation
(200b) is un-severed at each interruption in the perforated cut (200c). The
slicing rules (212)
or perfing rules (212) are circumferentially spaced apart on the cylindrical
circumference of
the die cutting cylinder (210) . The slicing rules (212) or perfing rules
(212) extend radially
outward of the die cutting cylinder (210). As the insulation (200a) is
conveyed past the die
cutting cylinder (210) , the die cutting cylinder (210) rotates to bring each
slicing rule (212)
or perfing rule (212) into forceful engagement with the insulation (200a), to
make a
penetrating cut in the insulation (200a) at each interval corresponding to a
length of a
segment (200a).
[0037] In Fig. 2D, the die cutting cylinder (210) has a cutting rule (214) for
every two
slicing rules (212) or perfing rules (212). The cutting rule (214) severs
entirely the insulation
(200b) at every interval of three segments (200a) to provide a corresponding
batt (200) of
three segments (200a) in length, as is the batt (200) disclosed by Fig. 2B.
Alternatively, in
Fig. 2E, the die cutting cylinder (210) has a cutting rule (214) for every
three slicing rules
(212)., or for every three perfing rules (212) . Each cutting rule (214)
severs entirely the
insulation (200b) at every interval of four segments (200a) to provide a
corresponding batt
(200) of four segments (200a) in length, as is the batt (200) disclosed by
Fig. 2A.
Alternatively, an increased number of slicing rules (212) or perfing rules
(212) can be added
onto an appropriately increased circumference of the die cutting cylinder
(210), which would
cut a larger number of segments (200a) for each complete rotation of the die
cutting cylinder
(210). Thus a lengthy batt (200) can be manufactured having more than four
segments (200a)
in length, as discussed with reference to Fig. 2A, or more than three segments
(200a) in
length, as discussed with reference to Fig. 2B.
[0038] Further, the segments (200a) may be completely severed, and re-adhered
along a corresponding cut (200c) and/or (200d) by an adhesive, for example, as
disclosed in
related and commonly owned US Application, Serial No. 10/690,295, entitled
SEPARABLE
FIBROUS INSULATION, filed October 21, 2003, hereby incorporated by reference.
See
also US Patents 6,083,594; 6,165,305 and 6,670,011, which are hereby
incorporated by
reference.
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[0039] Each batt (200) is precut along its length into partially divided
segments
(200a). Each segment (200a) has a desired R-value and thickness, and further
has a major
surface area to fill a band joist cavity between spaced apart joists (106).
Advantageously, the
partially divided segments (200a) remain connected to one another until, at an
insulation site,
they are separated or removed from the batt (200) as one or a group of a
selected whole
number of said segments (200a). They are individually removed by manually
tearing along a
cut (200c) where they are connected to one another. The invention eliminates
the need for a
tool, such as, a utility knife to cut and remove a segment (200a).
[0040] Another advantage of the invention is that the segments (200a) are
precut to
reduce scrap that would result from cutting the batt (200) into segments
(200a) that are either
too small or too generous in size. A further advantage of the invention is
that installation time
is saved by reducing the time for measuring and cutting the insulation to
desired sizes. A
further advantage of the invention is that the batt (200) is familiar to a
worker. Further the
batt (200) is convenient for having a length that is relatively easy to
handle. One or more
batts (200) of convenient batt lengths can be gathered in a kit of parts that
is relatively easy to
handle.
[0041] The insulation that is capable of compression has an expanded volume
due to
included air, within spaced apart, fibers or particles or foam of such
materials as, glass,
polymer or cellulose based fibers, particles or foam. An industry standard R-
value is a rating
number that is printed on the insulation. The R-value refers to the extent to
which the
insulation reduces the rate of heat transfer through the insulation. The R-
value typically
increases with increases in thickness and with increases in density of the
insulation for a
given material. When the insulation is installed, it is capable of compression
to fill a band
joist cavity having a width between joists (106), for example, on 12 inch
centers, 16 inch
centers, 17.7 inches or 24 inch centers. Further, the insulation is capable of
compression to
fill the band joist cavity having a length defined by the width of a joist
(106), either 9.5
inches fora 2xl0 joist (106), or 11.5 inches fora 2xl2 joist (106), or 13.5
inches fora 2xl4
joist (106), or 15.5 inches for a 2xl6 joist (106). Such a compression is in a
direction
transverse to the R-value and thickness, which would not substantially reduce
the R-value of
the insulation.
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[0042] According to an embodiment of the invention, each segment (200) has a
minimum dimension of at least somewhat greater than 9.5 inches wide, to adapt
by
compression in a band joist cavity having a length of 9.5 inches defined by
the width of 2x10
joists (106). For example, each segment (200) is 0.5 inches greater than 9.5
inches wide,
which makes each segment about 10.0 inches wide.
[0043] With reference to Fig. 2A, the batt (200) is made of four segments
(200a) that
are different than a segment (200a) of 12.5 inches long as shown in Fig. 2A. A
batt (200) of
four segments (200a) each of at least somewhat greater than 9.5 inches long,
for example, 10
inches long. The batt (200) of four segments (200a) in length, would be made
into a desired
batt length of about 40 inches long, instead of the batt length of 50 inches
shown in Fig. 2A.
Thus, 40 inches long is a convenient batt length, and a convenient folded batt
length, as is the
batt length of 50 inches long shown in Fig. 2A. According to an embodiment of
the
invention, a batt (200) is four segments long with lengths of the segments
(200a)
corresponding to either the widths or the lengths of the band joist cavities.
[0044] Similarly, a batt (200), as in Fig. 2B, of three segments (200a) having
lengths
of at least somewhat greater than 9.5 inches long, for example, 10 inches
long, instead of a
segment (200a) of 16 inches long as shown in Fig. 2B, would be made into a
desired batt
length of about 30 inches long, instead of the batt length of 48 inches long
shown in Fig. 2B,
and more allowing for dimensional tolerances and the widths of cuts (220c),
between three
segments (200a). Thus, 30 inches long is a convenient batt length, and a
convenient folded
batt length, as is the batt length of 48 inches long shown in Fig. 2B.
According to an
embodiment of the invention, a batt (200) is three segments long with lengths
of the segments
(200a) corresponding to either the widths or the lengths of the band joist
cavities.
[0045] According to another embodiment of the invention, each segment (200a)
has a
minimum dimension, in length, in either the batt of Fig. 2A, or the batt of
Fig. 2B, of at least
somewhat greater than 11.5 inches, for example, 12 inches, to adapt by
compression in a
band joist cavity of 11.5 inches long as defined by the widths of 2x12 joists
(106).
[0046] A batt (200), as in Fig. 2A, of four segments (200a) having lengths of
at least
somewhat greater than 11.5 inches long, for example, 12 inches, instead of a
segment (200a)
of 12.5 inches long shown in Fig. 2A, would be made into a desired batt length
of about 48
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inches long, and more allowing for dimensional tolerances and the widths of
cuts (220c),
between four segments (200a). Thus, 48 inches long is a convenient batt
length, and a
convenient folded batt length.
[0047] Similarly, a batt (200), as in Fig. 2B, of three segments (200a) having
lengths
of at least somewhat greater than 11.5 inches long, for example, 12 inches,
instead of a
segment (200a) of 16 inches long shown in Fig. 2B, would be made into a
desired batt length
of about 36 inches long, and more allowing for dimensional tolerances and the
widths of cuts
(220c), between three segments (200a). Thus, 36 inches long is a convenient
batt length, and
a convenient folded batt length.
[0048] According to another embodiment of the invention, each segment (200a)
has a
minimum dimension, in length, in either the batt of Fig. 2A, or the batt of
Fig. 2B, of at least
somewhat greater than 13.5 inches, for example, 14 inches, to adapt by
compression in a
band joist cavity of 13.5 inches long as defined by the widths of 2x14 joists
(106).
[0049] A batt (200), as in Fig. 2A, of four segments (200a) having lengths of
at least
somewhat greater than 13.5 inches long, for example, 14 inches, instead of a
segment (200a)
of 12.5 inches long in Fig. 2A, would be made into a desired batt length of
about 56 inches
long, and more allowing for dimensional tolerances and the widths of cuts
(220c), between
four segments (200a). Thus, 56 inches long is a convenient batt length and a
convenient
folded batt length.
[0050] Similarly, a batt (200), as in Fig. 2B, of three segments (200a) having
lengths
of at least somewhat greater than 13.5 inches long, for example, 14 inches,
instead of the 16
inches long shown in Fig. 2B, would be made into a desired batt length of
about 42 inches
long, and more allowing for dimensional tolerances and the widths of cuts
(220c), between
three segments (200a). Thus, 42 inches long is a convenient batt length, and a
convenient
folded batt length.
[0051] According to another embodiment of the invention, each segment (200a)
has a
minimum dimension, in length, in either the batt of Fig. 2A, or the batt of
Fig. 2B, of at least
somewhat greater than 15.5 inches, for example 16 inches, to adapt by
compression in a band
joist cavity of 15.5 inches long as defined by the widths of 2x16 joists
(106).
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[0052] A batt (200), as in Fig. 2A, of four segments (200a) having lengths of
at least
somewhat greater than 15.5 inches long, for example, 16 inches, instead of the
12.5 inches
long in Fig. 2A, would be made into a desired batt length of about 64 inches
long, instead of
the batt length of 50 inches long in Fig. 2A, and more allowing for
dimensional tolerances
and the widths of cuts (220c), between four segments (200a). Thus, 60 inches
long is a
convenient batt length and a convenient folded batt length.
[0053] Similarly, a batt (200), as in Fig. 2B, of three segments (200a) having
lengths
of at least somewhat greater than 15.5 inches long, for example, 16 inches,
would be made
into a desired batt length of about 48 inches long, and more allowing for
dimensional
tolerances and the widths of cuts (220c), between three segments (200a). Thus,
48 inches
long is a convenient batt length, and a convenient folded batt length.
[0054] According to another embodiment of the invention, each segment (200a)
has a
minimum dimension of at least somewhat greater than 14.5 inches, for example,
15 inches,
instead of the width of 16 inches shown in Fig. 2A, to adapt by compression in
a band joist
cavity of 14.5 inches wide between joists (106) on 16 inch centers. Such a
segment (200a)
can have a further minimum dimension of at least somewhat greater than 9.5
inches, for
example, 10 inches, to fill a band joist cavity of 9.5 inches long. The
segment (200a)would
measure at least somewhat greater than 9.5 inches by at least somewhat greater
than 14.5
inches.
[0055] To fill a band joist cavity of 11.5 inches long, or 13.5 inches long,
for
example, the segment (200a) is oriented such that its dimension of at least
somewhat greater
than 14.5 inches extends lengthwise in the band joist cavity of 11.5 inches
long or 13.5 inches
long. To fill a band joist cavity of 22.5 inches wide between joists (106) on
24 inch centers,
for example, two segments (200a) are oriented, as follows. One segment (200a)
of at least
somewhat greater than 14.5 inches, and another segment (200a) of at least
somewhat greater
than 9.5 inches, are oriented along the width of the band joist cavity, and
are compressed in
the length of the band joist cavity. Thus, according to the invention, a whole
number of one
or more of the segments (200a) adapt by compression to fill band joist
cavities of different
sizes.
12
CA 02493511 2005-01-20
[0056] A batt (200) of four segments (200a) each at least somewhat greater
than 14.5
inches long, for example, 15 inches, would have a convenient batt length of
about 60 inches
long and more allowing for dimensional tolerances and for the widths of cuts
(200c) between
the segments (200a). A batt (200) of three segments (200a) each would have a
smaller,
convenient batt length of about 45 inches long and more allowing for
dimensional tolerances
and for the widths of cuts (200c) between the segments (200a).
[0057] According to another embodiment of the invention, each segment (200a)
has a
minimum dimension, in width, in the batt of Fig. 2A, of at least somewhat
greater than 10.5
inches, for example, 11 inches, to adapt by compression in a band joist cavity
of 10.5 inches
wide between joists (106) on 12 inch centers. Such a segment (200a) can have a
further
minimum dimension, in length, in the batt of Fig. 2A, of at least somewhat
greater than 14.5
inches, for example, 15 inches, to fill a band joist cavity of 14.5 inches
wide. The segment
(200a)would measure at least somewhat greater than 10.5 inches by at least
somewhat greater
than 14.5 inches.
[0058] To fill a band joist cavity of 11.5 inches long, for example, the
segment (200a)
is oriented such that its dimension of at least somewhat greater than 14.5
inches extends
lengthwise in the band joist cavity of 11.5 inches long. To fill a band joist
cavity of 17.7
inches wide between joists (106) on 19.2 inch centers, for example, two
segments (200a) are
oriented the same, such that their respective dimensions of at least somewhat
greater than
10.5 inches, are oriented along the width of the band joist cavity, and are
further compressed
in the length of the band joist cavity. To fill a band joist cavity of 22.5
inches wide between
joists (106) on 24 inch centers, for example, two segments (200a) are oriented
differently,
such that one segment (200a) of at least somewhat greater than 14.5 inches,
and another
segment (200a) of at least somewhat greater than 10.5 inches, are oriented
along the width of
the band joist cavity, and are further compressed in the length of the band
joist cavity. Thus,
according to the invention, a whole number of one or more of the segments
(200a) adapt by
compression to fill band joist cavities of different sizes.
[0059] According to an embodiment of the invention, one or more segments
(200a)
adapt by compression in a width of 17.7 inches between joists (106) on 19.2
inch centers, or,
alternatively, in a width of 22.5 inches between joists (106) on 24 inch
centers. A minimum
of two segments (200a) are oriented beside one another, either in the same
orientation, or in
13
CA 02493511 2005-01-20
different orientations, and when their dimensions are added together, their
sum is at least
somewhat greater than 17.7 inches and 22.5 inches, respectively.
[0060] A batt (200) according to an embodiment of the invention has segments
(220a), each of which is 12.5 inches by 16 inches. Thus, according to Fig. 2A,
a batt (200) of
four segments (200a) long is made from a continuous insulation (200b) of 16
inches wide,
with each segment (200a) having a nominal dimension of 12.5 inches in length.
Then, the
batt (200) will have a desirable batt length of about 50 inches, allowing
extra length for
dimensional tolerances and for the widths of the numerous cuts (200c) between
four
segments (200a). Alternatively, a lengthy batt (200) of more than four
segments (200a) in
length is made, and then folded at each interval of desired batt length, or
each interval of four
segments (200a), which results in a batt length that is relatively easy to
handle.
[0061] Alternatively, according to Fig. 2B, the batt (200) of three segments
(200a)
long is made from a continuous insulation (200b) of 12.5 inches wide, with
each segment
(200a) being 16 inches in length and 12.5 inches wide.
[0062] Alternatively, a 25 inch wide continuous insulation (200b) is partially
divided
lengthwise, as in Fig. 2B, to provide a batt (200) of two segments wide, with
each segment
being 12.5 inches wide. Further, the 25 inch wide continuous insulation (200b)
is divided
completely lengthwise to provide two batts (200) each, of one segment wide.
Each batt (200)
of three segments (200a) having lengths of 16 inches, will have a desirable
batt length of
about 48 inches, allowing extra length for dimensional tolerances and for the
widths of the
numerous cuts (200c) between three segments (200a). Alternatively, according
to Fig. 2B, a
lengthy batt (200) of more than three segments (200a) in length is made, and
then folded at
each interval of desired batt length, or each interval of three segments
(200a), which results in
a batt length that is relatively easy to handle.
[0063] According to an embodiment of the invention, for example, a 12.5 inch
by 16
inch segment (200a) is removed from a batt (200) and is oriented with its 12.5
inch
dimension to adapt by compression in a band joist cavity of 10.5 inches wide,
as between
joists (106) on 12 inch centers. The 16 inch dimension of the segment (200a)
is further
compressed in a band joist cavity having, either a length of 9.5 inches
defined by the width
14
CA 02493511 2005-01-20
of 2x10 joists (106), or a length of 11.5 inches defined by the width of 2x12
inch joists
(106).
[0064] Alternatively, for example, the segment (200a) is oriented with its 16
inch
dimension to adapt by compression in a band joist cavity of 14.5 inches wide,
as between
joists (106) on 16 inch centers, and further, the 12.5 inch dimension is
compressed in a band
joist cavity having, either a length of 9.5 inches defined by 2x10 inch wide
joists (106), or a
length of 11.5 inches defined by 2x12 inch wide joists (106).
[0065] Alternatively, for example, two segments (200a) are removed from a batt
(200), and are oriented with their 12.5 inches spanning horizontally to adapt
by compression
in a band joist cavity of 17.7 inches wide, as between joists (106) on 19.2
inch centers, or,
alternatively, a band joist cavity of 22.5 inches wide, as between joists
(106) on 24 inch
centers. Further, the 16 inches dimension of two segments (200a) compress to
fill a band joist
cavity of 13.5 inches, as defined by the width of 2x 14 joists (106), or to
fill a band joist
cavity of 15.5 inches, as defined by the width of 2x16 joists (106).
[0066] The 16 inch dimensions of the segments (200a) are compressed to fill a
band
joist cavity having, either a length of 9.5 inches defined by the width of
2x10 inch wide joists
(106), or a length of 11.5 inches defined by the width of 2x12 inch wide
joists (106), or a
length of 13.5 inches defined by the width of 2x14 wide joists (106), or a
length of 15.5
inches defined by the width of 2x16 wide joists (106). Thus, segments (200a)
of 12.5 inches
by 16 inches adapt for compression in band joist cavities of various
dimensions defined by
joists (106) of different widths, and spaced apart on 12, 16, 19.2 or 24 inch
centers. The
segments (200a) of at least 16 inches in width or length have the further
advantage of filling
between joists on 12, 16, 19.2 or 24 inch centers, when the joists are less
than 1.5 inches
thick, wherein the joists are I -joists having web thicknesses of either 0.5
inches or 0.25
inches, or wherein the joists are open web joists which have tapered
thicknesses. This is
accomplished by either by keeping two segments together, or by using two
separate segments
side by side, and orienting the two segments as required to best fill a
corresponding band joist
cavity.
[0067] According to the invention, a continuous length (200b) of 16 inches
wide
insulation (200b) can be made into segments (200a) of at least somewhat
greater than 9.5, at
CA 02493511 2005-01-20
least somewhat greater than 10.5 inches, or at least somewhat greater than
11.5 inches long,
including and not limited to, 12.5 inches long, in a batt (200) according to
Fig. 2A. Further,
the segments (200a) are made into batts (200) adapted for relative ease in
handling. By
installing the segments (200a) in different orientations, the segments (200a)
adapt by
compression to fill band joist cavities of various lengths and widths. The
need for measuring
and cutting the insulation is reduced, and after removing one or more of the
segments (200a),
the remainder of the batt (200) has one or more remaining segments (200a),
which have
useful sizes, thereby avoiding a potential source of scrap.
PRESENTLY MANUFACTURED INSULATION
[0068] Another embodiment of the invention pertains to a method of making
presently manufactured insulation of different widths into segmented batts
(200) having
segments (200a) of insulation adapted for installation to fill band joist
cavities of different
sizes. Insulation is presently being manufactured in widths of 11, 15, 15.25,
16, 23, 23.25, 24
or 25 inches. These widths are exemplary only, as different manufacturers may
manufacture
insulation in different widths. The invention herein, is a method of making
presently
manufactured widths into segmented batts (200) according to Figs. 2A and 2B.
The
advantage is that no new insulation widths need to be manufactured. Further,
existing
insulation widths make different sizes of segments (200a), which adapt to fill
band joist
cavities despite the segments (200a) having different sizes due to being made
from different
widths of continuous insulation (200b).
[0069] First, the widths and lengths of band joist cavities is determined. In
Fig. 1A,
the width of a band joist cavity is 22.5 inches wide between 2x (two by)
joists on 24 inch
centers. The minimum width of one segment (200a) would be at least somewhat
greater than
22.5 inches wide to adapt by compression in the band joist cavity of 22.5
inches wide, or,
alternatively, a band joist cavity of 17.7 inches wide. Thus, presently
manufactured widths of
23, 23.25, 24 and 25 inches are made into segments (200a) having these
respective widths. A
band joist cavity shown in Fig. IA has a length of 9.5 inches, as defined by
2x10 inch wide
joists (106). A segment (200a) has a length of at least somewhat greater than
9.5 inches for
filling a band joist cavity as defined by 2x10 joists. Similarly, a segment
(200a) having a
length of at least somewhat greater than 11.5 inches is required for filling a
band joist cavity
11.5 inches long as defined by 2x12 joists. Similarly, a segment (200a) of at
least somewhat
greater than 13. 5 inches in length is required for filling a band joist
cavity as defined by 2x14
16
CA 02493511 2005-01-20
joists. Similarly, a segment (200a) of at least somewhat greater than 15.5
inches in length is
required for filling a band joist cavity as defined by 2x16 joists.
[0070] The width of a band joist cavity is 14.5 inches wide between 2x (two
by) joists
on 16 inch centers. The minimum width of a segment (200a)would be at least
somewhat
greater than 14.5 inches wide to adapt by compression in the band joist cavity
of 14.5 inches
wide, including, and not limited to, presently manufactured widths of 15,
15.25 or 16 inches.
Thus, presently manufactured widths of 15, 15.25 or 16 inches are made into
segments (200a)
having these respective widths. The lengths of such segments (200a) are at
least somewhat
greater than 9.5 inches, or at least somewhat greater than 11.5 inches, or at
least somewhat
greater than 13.5 inches, or at least somewhat greater than 15.5 inches, to
fill band joist
cavities as defined by respective 2x10, 2x12 2x14 or 2x16 joists (106).
[00711 Further, as previously described above, a 16 inch wide continuous
insulation
(200b) is adapted for making segments (200a) of 16 inches wide and 12.5 inches
long,
according to an embodiment of the invention. Such segments (200a) of 12.5
inches long
adapt by compression in band joist cavities of either 9.5 long or 11.5 inches
long. Similarly,
segments (200a) of 12.5 inches long are manufactured from insulation of 15,
15.25 and 16
inches wide, to be adaptable by compression in a band joist cavity of either
9.5 inches long or
11.5 inches long. Further, two segments (200a) are oriented to fill band joist
cavities defined
by 2x14 or 2x16 joists on 19.2 or 24 inch centers. Alternatively, the segments
(200a) of 15,
15.25 and 16 inches wide are at least somewhat greater than 9.5 inches long,
for example, 10
inches, to adapt by compression in band joist cavities 9.5 inches long.
Alternatively the
segments (200a) of 15, 15.25 and 16 inches wide are at least somewhat greater
than 11.5
inches long, for example, 12 inches, to adapt by compression in band joist
cavities 11.5
inches long, or in band joist cavities 9.5 inches long. Further, two segments
(200a) are
oriented to fill band joist cavities defined by 2x14 or 2x16 joists on 19.2 or
24 inch centers.
[0072] According to another embodiment of the invention, the width of a band
joist
cavity is determined, as being 10.5 inches wide between 2x (two by) joists on
12 inch centers.
The minimum width of a segment (200a) would be at least somewhat greater than
10.5 inches
wide, for example 11 inches, to adapt by compression in the band joist cavity
of 10.5 inches
wide.
17
CA 02493511 2005-01-20
[0073] The presently manufactured width of 11 inches, would adapt by
compression
in a band joist cavity of 10.5 inches wide between 2x (two by) joists (106).
Further, 2x10
joists (106) define a band joist cavity 9.5 inches long. A segment (200a) of
at least somewhat
greater than 9.5 inches long is made to adapt by compression in the band joist
cavity. Further,
2x12 joists (106) define a band joist cavity of 11.5 inches long. A segment
(200a) of at least
somewhat greater than 11.5 inches long, for example 12 inches, is made to
adapt by
compression in a band joist cavity of 11.5 inches long, or 9.5 inches long.
Further, the
presently manufactured width of 11 inches can be made into segments (200a) of
somewhat
greater than 14.5 inches long, including, and not limited to 15 and 16 inches
long, to adapt by
compression in a band joist cavity of either 10.5 inches wide or 14.5 inches
wide between
2x 10 joists (106). Two segments (200a) are oriented with their respective
dimensions of, 11.5
inches and somewhat greater than 14.5 inches long to adapt by compression in a
band joist
cavity of 17.7 or 22.5 inches wide between 2xl 0 joists. Accordingly
insulation of 11 inches
wide is adaptable to the present invention for 2x 10 joists (106).
[0074] According to another embodiment of the invention disclosed by Fig. 2B,
a
continuous length (200b) of insulation 25, 24, 23.25 and 23 inches wide are
presently being
manufactured, and can be adapted to manufacture batts (200) according to Fig.
2B. For
example, a 25 inch wide continuous length (200b) of insulation is partially
divided
lengthwise with a cut (200d) and then partially divided into three segments
(200a) long,
which provides a batt (200) of two 12. 5 inch segments (200a) wide and three
16 inch
segments (200a) in length. Alternatively, the batt (200) is of four segments
(200a) in length,
as in Fig. 2A. Thus each segment (200a) is 12.5 inches by 16 inches, according
to an
embodiment of the invention, as described above.
[0075] The width of each segment (200a) of at least somewhat greater than 11.5
inches wide, including and not limited to 12 inches wide, can be installed to
adapt by
compression in a band joist cavity of 10.5 inches wide. To adapt by
compression in a band
joist cavity of 14. 5 inches wide between joists (106) on 16 inch centers, the
segments (220a)
can be manufactured with a length of at least somewhat greater than 14.5
inches each,
including, and not limited to, a length of 16 inches each, for compression in
band joist
cavities of various dimensions defined by joists (106) of different widths,
and spaced apart on
12, 16, 19.2 or 24 inch centers.
18
CA 02493511 2005-01-20
[0076] Similarly, according to Fig. 2B, a 24 inches wide continuous length
(200b) of
insulation, can be partially divided or completely severed by a cut (200d)
lengthwise to
manufacture batts (200) of two segments (200a) wide, with each segment (200a)
being about
12 inches wide. Similarly, a 23.25 inches wide continuous length (200b) of
insulation, can be
partially divided or completely severed lengthwise to manufacture batts (200)
of two
segments (200a) wide, with each segment (200a) being at least somewhat greater
than 11.5
inches wide. Each of these segments (220a) would need to be at least somewhat
greater than
14.5 inches long, including and not limited to 15 and 16 inches, for
compression in a band
joist cavity between joists on 16 inch centers. Thus, a 23.25 inches wide
insulation would be
divided into two segments (200a) wide, with each segment being at least
somewhat greater
than 11.5 inches by at least somewhat greater than 14.5 inches, including and
not limited to
15 and 16 inches, for compression in band joist cavities of various dimensions
defined by
joists (106) of different widths, and spaced apart on 12, 16, 19.2 or 24 inch
centers.
[0077] Similarly, a 23 inches wide continuous length (200b) of insulation, can
be
partially divided or completely severed lengthwise to manufacture batts (200)
of two
segments (200a) wide, with each segment (200a) being near to 11.5 inches wide,
which
satisfies a requirement for a segment (200a) of at least somewhat greater than
10.5 inches for
compression in a band joist cavity between joists (106) on 12 inch centers.
Each of these
segments (220a) would need to be at least somewhat greater than 14.5 inches
long, including
and not limited to 15 and 16 inches, for compression in a band joist cavity
between joists on
16 inch centers. Thus, a 23 inches wide insulation would be divided into two
segments (200a)
wide, with each segment being 11.5 inches by at least somewhat greater than
14.5 inches,
including and not limited to 15 and 16 inches, for compression in band joist
cavities of
various dimensions defined by joists (106) of different widths, and spaced
apart on 12, 16,
19.2 or 24 inch centers.
[0078] Further, by installing two segments (200a) of at least somewhat greater
than
11.5 inches wide, or by installing two segments of about 12 inches wide, they
adapt by
compression in a band joist cavity having a width of either 17.7 or 22.5
inches between 2x
(two by) joists on 19.2 and 24 inch centers, respectively.
19
CA 02493511 2005-01-20
[0079] The present invention disclosed herein adapts different widths of
insulation
11, 15, 15.25, 16, 23, 23.25, 24 or 25 inches to manufacture batts (200) of
either four
segments (200a) long or three segments (200a) long, as convenient batt
lengths.
[0080] According an embodiment of the invention, each of the segments (200a)
is, at
least somewhat greater than 9.5 inches, by, at least somewhat greater than
14.5 inches, for
compression in band joist cavities of various dimensions defined by joists
(106) of different
widths, and spaced apart on 12, 16, 19.2 or 24 inch centers.
[0081] According another embodiment of the invention, each of the segments
(200a)
is, at least somewhat greater than 9.5 inches, including and not limited to,
somewhat greater
than 9.5 inches, 10 inches, somewhat greater than 10.5 inches, 11 inches,
somewhat greater
than 11.25 inches, near to 11.5 inches, somewhat greater than 11.5 inches, 12
inches, 12.5
inches and other presently manufactured widths, by, at least somewhat greater
than 14.5
inches, for compression in band joist cavities of various dimensions between
joists of various
widths, and spaced apart on 12, 16, 19.2 or 24 inch centers.
[0082] According another embodiment of the invention, each of the segments
(200a)
is, at least somewhat greater than 9.5 inches, by, at least somewhat greater
than 14.5 inches,
including but not limited to, somewhat greater than 14.5 inches, 15 inches,
15.25 inches, 16
inches and other presently manufactured widths, for compression in band joist
cavities of
various dimensions between joists of various widths, and spaced apart on 12,
16, 19.2 or 24
inch centers.
[0083] According another embodiment of the invention, each of the segments
(200a)
is, at least somewhat greater than 9.5 inches, including and not limited to,
somewhat greater
than 9.5 inches, 10 inches, somewhat greater than 10.5 inches, 11 inches,
somewhat greater
than 11.25 inches, near to 11.5 inches, somewhat greater than 11.5 inches, 12
inches, 12.5
inches and other presently manufactured widths, by, at least somewhat greater
than 14.5
inches, including but not limited to, somewhat greater than 14.5 inches, 15
inches, 15.25
inches, 16 inches and other presently manufactured widths, for compression in
band joist
cavities of various dimensions defined by joists (106) of different widths,
and spaced apart on
12, 16, 19.2 or 24 inch centers.
CA 02493511 2005-01-20
[0084] Further, according to the present invention, insulation (200b) of
different
widths will result in different sizes of segments (200a), which are adaptable
to insulate band
joist cavities despite being of such different sizes. Further, according to
the present invention,
a whole number of the segments (200a) fill a band joist cavity. The advantage
is that whole
segments (200a) are used without waste, and without having to measure and cut
them.
[0085] Fig. 2C discloses a kit of parts (202) having two or more batts (200)
together
in a group. According to an embodiment of the invention, each separate batt
(200) in the kit
of parts (202) is a desired batt length, for example, 50 inches long having
segments (200a)
measuring 12.5 inches by 16 inches. Further, each separate batt (200) in the
kit of parts (202)
is, either one segment (200a) wide as discussed with reference to Fig. 2A or
Fig. 2B, or two
segments wide, as discussed with reference to Fig. 2B. Further, the kit of
parts (202) can
comprise one or more lengthy batts (200), each being folded across its length
at each multiple
of the desired batt length. For example, a lengthy batt (200) that is longer
than the four
segments (200a) as discussed with reference to Fig. 2A, is folded at each
multiple of four
segments (200a) long to correspond with a desired batt length. Further, for
example, a
lengthy batt (200) that is longer than the three segments (200a) as discussed
with reference to
Fig. 2B, is folded at each multiple of three segments (200a) long to
correspond with a desired
batt length. Further, the kit of parts (202) having two or more batts (200)
can comprise one or
more of the separate batts (200) of either three or four segments long, and
one or more of the
folded lengthy batts (200) as described herein.
[0086] The kit of parts (202) having two or more batts (200) together in a
group is
packaged by having the two or more batts (200) being bound together with
strapping (204)
including, and not limited to, metal or plastic strap, tape or twine.
Alternatively, the kit of
parts (202) having two or more batts (200) together in a group is packaged by
being in
external packaging (206) including, and not limited to; a bag or a sheath
wrapper. Further, the
kit of parts (202) having two or more batts (200) together in a group, can be
compressed
together before being packaged. Then, the compressed batts (200) are packaged
to retain their
compression. The kit of parts (202) having two or more batts (200) together in
a group can be
packaged by the strapping (204) alone, or by the external packaging (206)
alone, or by a
combination of strapping (204) and the external packaging (206).
21
CA 02493511 2005-01-20
[0087] According to a further embodiment of the invention, a process of making
and
packaging the kit of parts (202), as previously described with reference to
Fig. 2C, is
performed in combination with process steps of manufacturing the batts (200),
as previously
described with reference to Figs. 2A, 2B, 2D and 2E. Thus, a process of
manufacturing the
batts (200) further includes the process of combining the two or more batts
(200) to make the
kit of parts (202), and further includes, the process of packaging the kit of
parts (202) by
combining the two or more batts (200) with the strapping (204) and/or with the
external
packaging (206). The process of manufacturing the batts (200) further includes
the process of
manufacturing two or more batts (200) that are separate from one another and
grouped
together in the kit of parts (202). Alternatively, the process of
manufacturing the batts (200)
further includes the process of manufacturing a lengthy batt (200) that is
partially divided
into multiple segments (200a), and folding the lengthy batt (200) at each
interval of a desired
batt length to form two or more batts (200) for the kit of parts (202).
[0088] Fig. 3 discloses a long band of insulation (300) for covering a length
and
width of the exterior joist (106a) disclosed by Fig. 1B. When a horizontal
span of the exterior
joist (106a) would be greater than a combination of whole number segments
(200a), a long
band of insulation (300) will be used to fill the span. For example, a long
band of insulation
(300) is required to cover the length and width of the exterior joist (106a).
Because the
exterior joist (106a) is 2x10 (1.5 inches by 9.5 inches) or 2x12 (1.5 inches
by 11.5 inches), or
2x 14 (1.5 inches by 13.5 inches) or 2x 16 (1.5 inches by 15.5 inches) a first
embodiment of a
long band of insulation (300) can measure not less than, and at least somewhat
greater than
9.5 inches wide, including and not limited to 10 and 11 inches wide, for
compression
vertically along a joist width of 9.5 inches. Further the long band of
insulation (300) can
measure at least somewhat greater than 11.5 inches wide, for example, 12
inches, for
compression vertically along a joist width of 11.5 inches and smaller. Further
the long band
of insulation (300) can measure at least somewhat greater than 13.5 inches
wide, for example,
14 inches, for compression vertically along a joist width of 13.5 inches and
smaller. Further
the long band of insulation (300) can measure at least somewhat greater than
15.5, for
example, 16 inches wide, for compression vertically along a joist width of
15.5 inches and
smaller. Further, for example, the long band of insulation (300) is supplied
in a continuous
length of, for example, 8 feet, which can be folded in half, or at each
interval of length
corresponding approximately to the length of a group of two or more batts
(200), for
example, of about 50 inches in length.
22
CA 02493511 2005-01-20
[0089] Fig. 4 discloses a kit of parts (400) according to the invention. The
kit of parts
(400) has one or more long bands of insulation (300) combined with one or more
batts (200).
Each batt (200) for the kit of parts (400) comprises any of the batts (200)
discussed with
reference to the kit of parts (200). Each long band of insulation (300)
insulates along an
exterior joist (106a) that supports a floor (108) or subfloor. Each batt (200)
is partially
divided into segments (200a) for insulating between joists (106). Each long
band of
insulation (300) is folded to have a folded length approximately the same
lengths as the batts
(200). Each of the long bands of insulation (300) and the batts (200) of a kit
of parts (400),
are in a group, and are packaged by being bound together with strapping (402)
of metal strap,
tape or twine, and/or by being in a bag or sheath wrapper (404), similarly as
the kit of parts
(202) discussed previously with reference to Fig. 2C.
[0090] Fig. 5 discloses a batt (200) having four segments (200a), as discussed
previously with reference to Fig. 2A, and further having the segments (200a)
and an attached
vapor barrier or vapor retarder (500). For example, the vapor retarder (500)
comprises a
facing that includes, and is not limited to; kraft paper, foil scrim kraft
paper, polymeric (PP,
polypropylene, PE, polyethylene, PS, polystyrene) film, foil, metal foil,
laminates thereof,
and combinations thereof. Bituminous asphalt is used primarily to adhere kraft
paper. Water
based adhesives and hot melt are used primarily to adhere foils and films.
[0091] The vapor retarder (500) is assembled to the continuous length (200b)
of
insulation, followed by cutting the vapor retarder (500) with perforations
(502)
simultaneously with cutting of the segments (200a) by the slicing rules (212)
or perfing rules
(212). Alternatively, the perforations (502) of the vapor retarder (500) are
cut separately from
the insulation segments (200a), followed by assembly of a cut vapor retarder
(500) and the
segments (200a) of the batts (200). The vapor retarder (500) covers one major
surface of the
segments (200a). The vapor retarder (500) is segmented with perforations (502)
at the same
intervals as the segments (200a) being covered by the vapor retarder (500).
Further, the vapor
retarder (500) has extended side margins (500a) that are perforated, and that
project beyond
opposite sides of the segments (200a) for stapling to adjacent joists (106).
Similarly, each of
the batts (200) as discussed with reference to Fig. 2A and Fig. 2B is provided
with a vapor
retarder (500). Alternatively, each of the batts (200) as discussed with
reference to Fig. 2A
and Fig. 2B is without a vapor retarder (500).
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CA 02493511 2005-01-20
[0092] The vapor retarder (500) can be manually torn along its perforations
(502) to
separate adjacent segments (200a) from one another. When a wide band joist
cavity is large
enough to be filled with two or more segments (200a) covered by the vapor
retarder (500),
then, the vapor retarder (500) would have exposed perforations (502) that are
exposed after
being installed in a band joist cavity. A seal, including and not limited to,
adhesive or tape,
can be installed to cover the exposed perforations (502). Alternatively, a
removable adhesive
or tape can be applied immediately after manufacture of the perforations
(502).
[0093] Although the invention has been described in terms of exemplary
embodiments, it is not limited thereto. Rather, the appended claims should be
construed
broadly, to include other variants and embodiments of the invention, which may
be made by
those skilled in the art without departing from the scope and range of
equivalents of the
invention.
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