Note: Descriptions are shown in the official language in which they were submitted.
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DEVICE AND METHOD FOR ATTACHMENT OF INSULATION
The instant application claims benefit of prior U.S. Provisional Application
Ser No.
61/251,791 filed on October 15, 2009.
BACKGROUND
US Patent Application No. 20040128930A1 discloses a heat insulating wall
structure in
which a cold (thermal) bridge is prevented by reducing heat conduction to a
metal
framework and the rust of the framework and internal dew condensation can be
prevented.
U.S. Patent Nos 6,523,324 and 6,698,157 each disclose insulated panels for
building systems.
U.S. Patent Application No. 20040111997 discloses a foam wall panel system
with a Z-
shaped wall panel connection device. The Z-shape of the wall panel connection
device
provides cavities on each side which accept the angled edges of foam wall
panels that fit
within the cavities. Adjacent foam cores having angled edges are secured into
the cavities on
opposite sides of Z-shaped wall panel connection devices to form a continuous
foam wall.
U.S. Patent No. 5,758,464 discloses a plurality of insulating panels for
installation between
and insulation of the metal furrings of a wall system. Preferred panels have a
plastic foam
core. The vertical side edges of the panels are provided with kerfs for
enclosure of the metal
furrings and reduction of the thermal bridging conventionally caused by the
furrings.
U.S. Patent Application No. 20060185301 discloses a tie clip used to hold a
plurality of
preformed insulated concrete forms together. The tie clip could be a definite
length of nine
gauge high carbon hanger wire comprising a front portion, a rear portion, a
front bend, a
middle bend, and a rear bend.
SUMMARY
Attachment of insulation to building structures often suffers from thermal
bridges, which
conduct hot or cold air through the insulation, and thus, lead to loss of
thermal efficiency of
the insulation.
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In one aspect, there is provided a thermal break clip for securing insulation
between a first
construction surface and a second construction surface, the thermal break clip
attached to the
first and second construction surfaces, wherein the thermal break clip is
constructed of non-
heat conducting material. A thermal heat clip may be conducted of plastic.
Insulation may
consist of thermal insulation boards.
In addition, a thermal break clip may have: a first portion; second portion;
and a central
portion, wherein the first portion attaches to the first construction surface,
the second portion
attaches to the second construction surface; the first and second portions are
joined through
the central portion; and the insulation is positioned between the first and
second portions.
Furthermore, the second portion may be substantially parallel to the first
portion, and the
central portion may be substantially perpendicular to the first and second
portions. In
addition, the first portion may extend in the same or opposite direction of
the second portion
relative to the central portion. Or, the first portion may extend above a
plane defined by the
central portion; while he second portion may extend both above and below the
plane. In the
latter case, the insulation is positioned both above and below the plane
defined by the central
portion. The first portion or the second portion may be flexibly attached to
the central
portion. It is possible for the central portion to include a plurality of
steps, each step
substantially perpendicular to the first and second portions.
A thermal break clip may be attached to the first construction surface or the
second
construction surface with a perforation means (such as, but not limited to,
screws, nails and
the like). Or, a thermal break clip may be attached to the first construction
surface or the
second construction surface with an adhesive.
In a further aspect, there is provided a thermal break clip for securing
insulation between a
first construction surface and a second construction surface, the clip having
a first leg; a
second leg; and a central portion; the first leg substantially parallel to the
second leg; the
central portion substantially perpendicular to the first and second legs; the
first leg and
second leg extending above a plane defined by the central portion; the first
leg attached to the
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first construction surface; the second leg attached to the second construction
surface; the
insulation positioned between the first and second legs, wherein the clip is
constructed
substantially of non-heat conducting material. The insulation may consist of
thermal
insulation boards.
In yet another aspect, there is provided a thermal break clip for securing
insulation between a
first construction surface and a second construction surface, the clip having
a first leg; a
second leg; and a central portion; the first leg substantially parallel to the
second leg; the
central portion substantially perpendicular to the first and second legs; the
first leg extending
above a plane defined by the central portion; the second leg extending above
and below the
plane; the central portion having one or more steps, each step substantially
perpendicular to
the first and second legs; the first leg attached to the first construction
surface; the second leg
attached to the second construction surface; the insulation positioned between
the first and
second legs both above and below the plane, wherein the clip is constructed
substantially of
non-heat conducting material. The insulation may consist of thermal insulation
boards.
In yet a further aspect, there is provided a method of securing insulation
between a first
construction surface and a second construction surface, the method comprising:
a) attachment
of a plurality of base thermal break clips to the first construction surface,
each base thermal
break clip having an opening to receive the insulation; b) positioning a first
portion of the
insulation into a subset of the plurality of base thermal clips; c)positioning
of a plurality of
intermediate base clips onto the first set of insulation, each of the
intermediate thermal break
clips having a first and second opening for receiving insulation, and each
intermediate
thermal break clip being attached to the first construction surface;
d)positioning of a second
portion of insulation onto the second openings of the intermediate thermal
break clips; e)
repetition of steps c and d until the first construction surface is
substantially covered by the
insulation; and attachment of the second construction surface to the plurality
of base and
intermediate thermal break clips; wherein the base thermal-break clips and
intermediate
thermal-break clips are constructed of non-heat conducting material. Examples
of a first
construction include, but are not limited to, a concrete wall; a metal deck; a
drywall board;
and vertical strapping attached to wood siding. Examples of a second
construction surface
include, but are not limited to, wood studding, a drywall board and a fibre
board.
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Alternatively, a second construction surface may be brick cladding, with an
air gap present
between the thermal break clips and the brick cladding.
In yet another aspect, there is provided an insulation system comprising: a
plurality of base
thermal-break clips, a plurality of intermediate thermal-break clips; a
plurality of insulation
boards; a first construction surface and a second construction surface, the
base and
intermediate thermal-break clips being constructed of non-heat conducting
material, wherein:
the insulation boards are paired and ship-lapped; the intermediate thermal-
break clips connect
adjacent pairs of ship-lapped insulation; the paired insulation boards are
positioned into each
of the plurality of base thermal-break clips; the intermediate and base
thermal-break clips are
attached to the first construction surface, thereby securing the plurality of
insulation boards
to the first construction surface; and the construction surface is attached to
the intermediate
and base thermal-break clips.
BRIEF DESCRIPTION OF FIGURES
Figure 1 illustrates a perspective view of a first embodiment.
Figure 2 illustrates a perspective view of a second embodiment.
Figure 3 illustrates a sectional view of a first application of a thermal
break clip.
Figure 4 illustrates a sectional view of a second application of a thermal
break clip.
Figure 5 illustrates a sectional view of a third application of a thermal
break clip.
Figure 6 illustrates a sectional view of a fourth application of a thermal
break clip.
DESCRIPTION OF EMBODIMENTS
Referring to Fig. 1, a first embodiment of a thermal clip (10) is shown with a
first (15) and
second (20) leg joined through a central portion (25). The first leg (10) has
an aperture (30)
along its length, for reception of a screw (not shown), nail (not shown), or
similar attachment
means. The first leg (15) is attached to a first construction surface (not
shown).
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The legs (15, 20) can have equal or unequal height. In the embodiment
illustrated in Fig. 1,
the height (35) of the second leg (20) is less than the height (40) of the
first leg (15). This
allows for use of a tool (for example, but not limited to, a screw gun,
hammer, etc) for
securing the attachment means (not shown) through the aperture (30). As such,
the height
(35) of the second leg lies below the aperture (30) to allow for use of an
application tool (not
shown).
In addition, the second leg may also have an aperture, for attachment to a
second construction
surface. It is also understood that each leg of the thermal clip can include
one or more
apertures.
Alternatively, a thermal clip of the instant application can be attached using
means that do not
require an aperture. An example of means is, but not limited to, an adhesive.
In a case where
an adhesive is used to secure a leg to a construction surface, there is no
aperture in such leg of
the thermal clip.
The length (45) of the central portion (25) is at least equal to the width of
insulation (not
shown) used. The width (50) of the thermal clip is not limited to any
particular range. As an
example, where insulation boards are used, the width (50) of the thermal clip
(10) is at least
equal to the total thickness of the insulation boards used.
The second leg can be flexibly attached to the central portion, so that the
second leg can be
folded out (in a direction away from the first leg), to allow for insulation
to be installed
within the clip. The second leg can then be folded back to its original
position.
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Alternatively, the central portion (25) may be staggered, rather than planar,
to accommodate a
staggered arrangement of insulation. As an example, the insulation can consist
of a plurality
of insulation boards that are ship-lapped.
The insulation is positioned in the opening defined by the two legs (15, 20)
and the central
portion (25).
Referring to Fig. 2, a second embodiment of a thermal clip (60) is shown with
a first (65),
second (70) and third (75) legs joined through a central portion (80). The
first leg (60) has an
aperture (85) along its length, for reception of a screw (not shown), nail
(not shown), or
similar attachment means. The first leg (65) is attached to a first
construction surface (not
shown). In this embodiment, insulation is positioned in both of the openings;
i.e. the thermal
break clip abuts between two pieces of insulation. One opening is defined by
the legs (65, 70)
and the central portion (80). The other opening is defined by the leg (75) and
central portion
(80).
The first and second legs (65, 70) can have equal or unequal height. In the
embodiment
illustrated in Fig. 2, the height (90) of the second leg (70) is less than the
height (95) of the
first leg (65). This allows for use of a tool (for example, but not limited
to, a screw gun,
hammer, etc) for securing the attachment means (not shown) through the the
aperture (85).
As such the height (90) of the second leg lies below the aperture (80) to
allow for use of an
application tool (not shown).
The third leg (75) is generally aligned with the second leg (70), and extends
below the central
portion (80). The third leg can be used to secure or hold insulation from
below. In addition,
the third and second legs can be combined into one continuous leg, extending
both above and
below the central portion (80).
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In addition, the second and third legs may each have one or more apertures,
for attachment to
a second construction surface. It is also understood that each leg of the
thermal clip can
include one or more apertures, as needed.
Alternatively, a thermal clip of the instant application can be attached using
means that do not
require an aperture therein, such as, but not limited to, an adhesive. In such
case, where an
adhesive is used to secure a leg to a construction surface, there is no
aperture in such leg of
the thermal clip.
Another embodiment of a thermal clip of the instant application (not shown) is
a variation of
the embodiment shown in Fig. 1. The second leg, rather than being on the same
side as the
first leg relative to the central portion, is on the opposite side relative to
the central portion.
This type of arrangement is also known in the art as a butt joint.
In Fig. 2 central portion (80) is shown with a step-type geometry, for use
with insulation,
such as insulation boards that are staggered (or ship-lapped). The embodiment
shown in Fig.
2 is for use with two insulation boards, and therefore, the central portion
(80) has two steps,
one for each insulation board (not shown). The width of each step (97, 98) is
at least equal to
the thickness of each insulation board. The height (99) of the step is at
least equal to the
offset distance of the ship-lapped boards. While a step-type geometry is shown
in Figure 2,
the central potion can also have a planar geometry (as in Figure 1), for board
insulation that is
stacked aligned, rather than staggered (or ship-lapped).
The central portion can be designed to hold a plurality of insulation boards.
The width (100) of the thermal clip is not limited to any particular range.
The thermal clip (60) illustrated in Fig. 2 is made of material that does not
conduct heat, such
as, but not limited to, plastic, recycled plastic, propylene, and the like.
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A method of securing insulation between two construction surfaces is as
follows:
1) One or more insulation boards are secured to an edge of the first wall
using a plurality of
thermal break clips with the general shape as shown in Fig. 1 (with or without
apertures).
These thermal break clips are attached to the wall surface, and, optionally to
any adjacent
structural surface (e.g. a base or floor, or adjacent wall).
2) Insulation boards are then positioned into the openings of the attached
thermal clips.
Further boards are attached to an adjacent set of insulation boards using a
plurality of thermal
clips with the general shape as shown in Fig. 2 (with or without apertures).
These thermal
clips may be referred to as intermediate thermal break clips. The intermediate
thermal break
clips are attached to the wall surface. Installation of the insulation boards
continues until the
wall is covered with insulation.
3) A second construction surface is then applied and secured to the
insulation/thermal break
structure, so that insulation is now between the wall and the construction
surface.
Figures 3 to 6 provide examples of using a thermal break clip to secure
insulation in a
number of settings.
Figure 3 illustrates a concrete wall application of a thermal break clip
(125), for securing
insulation (110) between a concrete wall (115) and drywall (105). The
insulation (110) is
ship-lapped, and consists of two insulation boards. The thermal break clip
(125) is secured to
the drywall (105) with a drywall screw (120), and secured to the concrete wall
(115) with a
screw (130).
Figure 4 illustrates a brick wall application of a thermal break clip (150),
for securing
insulation (145) between exterior brick cladding (165) and wood studding
(140). The
insulation (145) is ship-lapped, and consists of two insulation boards. The
thermal break clip
(150) is secured to the wood studding (140) with a first screw (170), and
secured to the brick
cladding (165) with a galvanized brick tie (160). There is a layer of space
(155) between the
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secured insulation (145) and the exterior brick cladding (165). The thermal
break clip (150) is
further secured to the insulation (145) through the perforation attachment
means (175).
Figure 5 illustrates a roof application of a thermal break clip (200), for
securing insulation
(190) between a metal roof deck (210) and a fibre board (185). The insulation
(190) is ship-
lapped, and consists of two insulation boards. The thermal break clip (200) is
secured to the
fibre board (185) with a drywall screw (195), and secured to the roof deck
(210) with two
self-tapping screws (205). A weatherproof membrane (180) is placed adjacent
the fibre board
(185).
Figure 6 illustrates a wood siding application of a thermal break clip (265),
for securing
insulation (260) between wood studding (255) and vertical strapping (270)
which is adjacent
to wood siding (275). The insulation (260) is ship-lapped, and consists of two
insulation
boards. The thermal break clip (265) is secured to the wood studding (255)
with a first screw
(280), and secured to the strapping (270) with a second screw (285).
While specific embodiments have been described in detail in the foregoing
detailed
description and illustrated in the accompanying drawings, those with ordinary
skill in the art
will appreciate that various modifications and alternatives to those details
could be developed
in light of the overall teachings of the disclosure. Accordingly, the
particular arrangements
disclosed are meant to be illustrative only and not limiting as to the scope
of the invention,
which is to be given the full breadth of the appended claims and any and all
equivalents
thereof.
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