Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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IMPROVED BUILDING CONSTRUCTIONS USING BEAMS AND RELATED
METHOD
FIELD OF THE INVENTION
The present invention relates generally to the construction
of buildings using beams, such as wall studs, floor joists,
and ceiling rafters, and, more particularly, to a method
for constructing such structures with a layer of foam
material positioned between the beams and overlying panels.
The studs, joists and rafters may be made of wood or metal.
BACKGROUND OF THE INVENTION
Buildings are generally constructed with floors, walls,
ceilings, or roofs made of beams and panels which overlie
or covEr the beams. A problem which is encountered in
constructing such buildings is the frequent development of
squeaks.
In many structures, floors are constructed by installing a
series of narrow joists--either metal or wooden--to provide
support, and then placing panels of plywood or similar
material on top of these. In this type of construction,
squeaks often develop where a gap between the joist and the
plywood permits the plywood to flex up and down as a person
walks across the floor. Because it is usually necessary to
remove carpeting and/or a
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ceiling to get at the sourwe o.f the problem, repairing such
squeaks is usually v~=_ry expensive.
The conventional measure which has been adopted to combat
this problem has been to glue the panels of plywaod to the
joists. This technique has been marked by only very modest
success. For example, in the case of wooden floor joists, as the
wood dries out, the warpage frequently becomes so great that the
glue line simply breaks and the glue therefore becomes
ineffective. Also, because such glues set up within a limited
period of time, construction workers must place the panels on the
joists almost immediately after the glue has been dispensed,
~lhich interferes with flexibility in managing the construction
tasks of the projects. Furthermore, in very hot or cold
climates, the glue tends to set up quickly, which aggravates this
problem. Also, most such glues cannot be used when it is
raining. Finally, when the panels are slid into place along the
tops of the joists the glue is often scraped off, leaving bare
spots where no glue is left to form a~bond, making this
conventional technique even less effective.
Accordingly, there exists a need for a method of
constructing floors which effectively eliminates the developnent
of squeaks. Furthermore, there is a need for such a method which
is economical and convenient to practice, and which can be used
in a wide range of environmental conditions.
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Metal wall studs, f1_cor joists and ceiling :rafters,
collectively referred to below as metal beams, offer builders and
owners many significant economic and other advantages over
traditional wooden beams (e.g., 2x4's, 2x10's, etc.). For
example, such metal beams tend to be stronger and more resistant
to deterioration. As a result, construction using metal beams is
becoming increasingly common in both residential and commercial
building.
Despite the inherent advantages which metal beams offer,
metal construction has exhibited a number of drawbacks in
practice. In particular, because the metal beams are highly
thermally conductive, they tend to conduct heat away from the
siding, flooring, sheet rock, or other panel covering much faster
than would corresponding wooden beams; for example, the thermal
conductivity of typical steel studs and other metal beams is
about 320 btu/ft2/hr/°F, as compared to a typical figure of about
120-140 btu/ft2/hr/°F for wood. As a result, "cold spots" are
formed on the outer surface of the wall or floor covering,
usually in the form of a series of spaced apart lines or bands
which correspond to the arrangement of the underlying metallic
beams comprising the metal framing. This tendency to conduct
heat away from the wall or floor covering is increased by the
normal practice of securing the materials together with metal
fasteners (for example, screws) ,
Several additional problems stem from the high thermal
conductivity of structures made using metal beams. Firstly, the
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cold spots cause condensation to form on the panel surface of the
structure's exterior; this can often he observed as a series of
vertical bands along the side of the structure. This leads to
accelerated deterioration of paint or other finishes in these
areas, and, also, (especially in cooler climates) fosters the
growth of mildew which is both unsightly and difficult to
eradicate. In addition, the moisture tends to be drawn into the
panel along the metal beam, and will sometimes actually migrate
along the metal beam into adjacent wooden supports, resulting in
rot problems and, after prolonged exposure to moisture, the metal
beams may rust.
Another problem which may develop from the thermal
conductivity of metal studs, joists, and rafters is that the
thermal integrity of the structure may be severely compromised.
Specifically, the metal studs may conduct heat away from the
interior of the house and out through panel walls, greatly
reducing the house's energy efficiency.
Some attempts have been made to deal with the problems
described above by using a metal foil which covers the inner
surface of the wall or floor covering. Unfortunately, possibly
owing to thermal conductivity of the foil material itself, this
solution has generally proven ineffective, and in some cases
appears to have actually aggravated the problem, especially by
tending to draw moisture more rapidly into the wall. In
addition, the foil and the beams generally are made of dissimilar
metals. This dissimilarity causes electrolysis to occur between
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the metal beams and the metal foil, which in turn weakens the
metal beam over time. I:~inally, the cost of the foil material
renders this approach prohibitively expensive.
As a result, there exists a need for an effective and
economical solution to the problems which are posed by the
thermal conductivity of metal frame construction, as these have
been described above.
SUMMARY OF INVENTION
The present invention has solved the problems cited above,
and, according to one aspect of the invention, comprises a
building with floors, walls, roofs, and ceilings from panels
attached to beams. At least two of the beams have a layer of
foam material on their edges, and each panel covers a substantial
longitudinal portion of the two beams while also spanning the
beams. The beams can be joists, studs, or rafters, and can be
made of metal or wood. The panels typically are far thinner than
the beams (panels typically about 1/4 inch to 1 inch in thickness
and beams at least 1.5 inches thick) and usually come in 4 by 8
toot sheets. In a preferred embodiment, the panel will have both
a width and a length in excess of the spacing of the beams.
The foam material according to another aspect of the
invention, includes a resiliently compressible material. The
foam material can also be formed into an adhesive tape with a
slick, non-adhesive outer layer which faces out from the beam
when the tape is adhered to the beam's edge.
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According to still another aspect of the invention, the foam
material comprises a thermally insulating material which forms a
thermal barrier between the panels and the beams on which the
insulating material is disposed.
S Yet another aspect of the invention is a specially adapted
beam which includes the foam material on an edge of the beam.
According to still another aspect of the invention, a
plurality.of the above described beams are assembled into frame
structures for walls, floors, ceilings, or roofs, with the layer
of foam material disposed on predetermined edges of the frame
structure in accordance with the particular usage contemplated
for the frame structure at the job site.
Another aspect of the invention involves a method of
constructing floors, walls, ceilings, or roofs of buildings. The
method includes the steps of installing a plurality of beams,
depositing the foam material onto the edges of at least two of
the beams, and covering a substantial longitudinal portion of the
two beams with one or more panels. The panels also span the
beams generally perpendicularly to the longitudinal direction of
the beams.
Another aspect of the present invention is a method of
eliminating squeaks in a floor by depositing a resiliently
compressible material on at least two joists and covering the
joists with panels which span the joists and cover a substantial
longitudinal portion of the joists. Fasteners are driven through
the panel, through the resiliently compressible material, and
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into the joists, thereby partially compressing the compressible
material and preventing any movement of the panels relative to
the joists which might cause squeaks.
Yet another aspect of the present invention is a method of
attaching a panel to a metal beam by depositing a thermally
insulating material on the metal beam and mounting the panel to
the beam to sandwich the insulating material between the beam and
the panel. A thermal barrier is thus formed between the panel
and the beam.
Further, objects and advantages of the invention in addition
to those described above will be understood by a reading of the
detailed description of the invention and a review of the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing a portion of a
building, such as the frame structure of a wall, built in
accordance with an aspect of the present invention;
FIG. 2 is a perspective view showing a larger portion of the
building of FIG. 1 built in accordance with the present
invention;
FIG. 3 is a perspective view showing the construction of the
wall of FIGS. 1 and 2;
FIG. 4 is a cross-sectional view of the wall of FIGS. 1-3;
FIG. 5 is an enlarged perspective view of a section of a
beam of the present invention;
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FIGS. 6A and 6B area perspective views showing the formation
of the beam of FIG. S;
FIGS. 7 and 8 are perspective views of a portion of another
frame structure, such as a floor, built in accordance with
another aspect of the present invention;
FIG. 9 is a plan view showing the floor of FIGS. 7 and 8;
FIG. 10 is an end view of the floor of FIG. 9;
FIG. 11 is a perspective view showing a method of
constructing another frame structure in accordance with the
present invention;
FIG. 12 is a perspective view of a portion of the structure
of FIG. 11;
FIG. 13 is a perspective view of the frame structure of
another wall embodying the present invention; and
Z5 FIG. 14 is a cross-sectional view taken along line 14-14 of
FIG. 11.
DETAILED DESCRIPTION
a. Overview
As shown in FIGS. 1 and 2, a frame structure, such as a wall
21, built in accordance with the present invention, includes a
series of metal beams 16, which act as wall studs. The metal
beams 16 are attached to a rim joist 17 or other suitable
support. The metal beams 16 are generally rectangular in cross
2S section, and have vertically extending outer faces 19. A panel
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26 (FIG. 2) , such as a sh2~~et of :a~:111-.oc~ar.<.:22, is secured to the
outer faces 19 of the beams 16.
A foam material 22 i:~ disposed on the outer faces 19 of the
metal beams 16. As will be described in greater detail below,
the foam material 22 may be a thermally insulating material, a
resiliently compressible material, or a material exhibiting both
properties simultaneously, depending on the particular
requirements of the building. Polyvinyl chloride, polyethylene,
or rubber foam are suitable for the material 22 and exhibit both
superior thermal insulation and resilient compressibility
properties.
The foam material 22 is formed into a strip of tape 20. The
bottom surface of the tape 20 is provided with a layer of
adhesive by which the tape 20 is affixed to the outer face 19 of
the beam 16, and the top of the tape 20 is preferably provided
with a slick, tough, non-adhesive top layer 24, which may
suitably be formed of Mylar'" or other slick, tough, non-adhesive
material.
The panel 26 (Fig. 2) has portions which overlie the metal
beams 16 so that the tape 20 is sandwiched between the beams 16
and the overlying portions of the panel 26. The slick,
non-adhesive top layer 24 of the tape 20 permits the panel 26 to
be slid back and forth into position. Fasteners 28, such as
screws, are then driven through the panel 26 and into the beams
16 so as to secure the panel of wallboard 26 in place, as can be
seen in FIG. 3. Additional panels (not shown) are attached in a
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similar manner and adjacent to the panel 26 to overlie the beams
16 and form the wall 21.
Each of such panels 26 are sufficiently wide and long to
span a plurality of beams while covering a substantial
S longitudinal portion of the beams. For example, currently,
standard panels are 4 feet wide by 8 feet long and will therefore
cover either 4 or 7 beams laid on 6-inch centers while extending
along respectively 8 feet or 4 feet of the longitudinal portions
of the beams. Such panels, when cut down from 4 x 8 feet panels
l0 or otherwise obtained, are always substantially longer and wider
than the width or thickness of the beams 16, whether the beams
are joists, studs, or rafters.
As the panel 26 is attached to the beam 16, the tape 20 is
partially compressed so as to fill any irregularities and gaps
1S between the studs 16 and the portions of the wallboard 26
overlying the studs 16, as shown in FIG. 4, so as to provide a
continuous, insulating layer between the two. Because of its
insulating qualities, the tape 20 serves as a thermal break which
interrupts the conductive contact between the beams 16 and the
20 overlying portions of the panel 26. Since this prevents heat
from being conducted away from the panel 26 and through the studs
16, the formation of "cold spots" is virtually eliminated. This,
in turn, eliminates condensation which has led to the problems
described above.
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The tape 20 also serves functions in addition to providing a
thermal break, depending on the nature of the structure in which
it is used. In particular, when used in the construction of a
floor 50, as shown in Figs 7-10, tape 60 includes the same foam
material 22 described with reference to the tape 20. The foam
material comprises a resiliently compressible material which
compensates for or "smooths out" irregularities and
discontinuities between joists 52 and overlying panels 66 of
plywood flooring. This usage of the tape 60 eliminates any gaps
which would otherwise permit the panels 66 to work up and down
and cause squeaks.
b. Insulating Material
FIG. 5 shows a short segment of the tape 20 adhered to a
section of the beam 16, arid illustrates, in enlarged detail, the
various layers of material of which the tape 20 is composed. The
tape 20 includes a layer of foam material 22 which exhibits
superior thermal insulation qualities and adequate product life
for permanent installation in a structure. The material 22 is
sufficiently soft and thick that it resiliently compresses
between the beam 16 and the overlying portion of the panel 26 of
wallboard or other covering tFIGS. 2 and 4) so as to fill any
gaps, but without being so severely compressed as to lose its
insulating qualities.
Thus, as shown in FIG. 4, when the panel 26 is installed
using fasteners 28, the foam material 22 compresses to a certain
degree, for example, down to about 500 of its original thickness.
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riocrever, even when partially compressed, it retains the ability
to provide a thermal break and the re:ailience necessary to fill
any gaps between the two members. The foam material 22 also
inhibits passage of moisture, and thereby reduces any potential
for rust on the metal beams l6 which may form after prolonged
periods of exposure to moisture.
Polyvinyl chloride (PVC) foam, closed-cell polyethylene
foam, and rubber foam have proven to be eminently suitable
materials for the foam material 22 in the present invention.
Unlike conventional glue, these materials retain their resilience
indefinitely, with the service life of these materials being
roughly equivalent to that of the structure itself. Moreover,
they exhibit excellent thermal insulation qualities; for example,
the conductivity of a 1/e" thick layer of the PVC foam material
is about 2.24 btu/ft2/hr/°F, as compared to 320 btu/ftz/hr/°F
for
uninsulated metal.
The thickness of the foam material 22 will vary somewhat
depending on the softness and insulating qualities of its
constituent material, as well as the size of the gaps between the
beams 16 and the corresponding paneling 26 which the material 22
will be expected to fill. When using the PVC or polyethylene
materials described above, suitable uncampressed thicknesses for
the material 22 have been found to range to about 1" thick
maximum, with about 1/16" to 1/8" being preferred.
The width of the tape 20, in turn, preferably corresponds
generally to the width of the edge of the beam 16 on which it is
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to be installed; for standard metal studs used in
residential construction, a width of about 1 7/16" is
suitable, whereas a width of about 3 1/4" is suitable for
the Wider joists 52 common in the flooring 50 ( FIGS. 7-
10). In addition to the above-described widths, the tape
can be any width required for the particular application.
The tape 20 has an adhesive bottom surface 30 (FIG. 5)
which is impregnated or coated with a suitable adhesive
material, such as a rubber-based pressure sensitive
adhesive. The adhesive material facilitates the laying the
strips of the tape 20 on the beams 16 and acts to hold the
strips in place while the paneling 26 (FIG. 2) , 66 (FIG. 8)
is being installed. The adhesive is preferably
sufficiently soft and sticky to adhere to the beam 16 (FIG.
5) even if it is somewhat damp. The density of the
adhesive can be adjusted somewhat depending on the desired
characteristics and intended use of the material; for
example, higher adhesive densities may be preferred where
it a.s to be applied to relatively wet or rough surfaces,
while lower densities may be preferred where a.t is desired
to make a.t easier to peel the tape 20 when it is stored in
a roll (see FIGS 6A & B). Also, in some embodiments, it
may be preferable to encapsulate at least a portion of the
adhesive material in closed cells within the foam layer 22
and the tape 20, such cells being configured to rupture
under the pressure which is applied as the tape 20 is
pressed against the beam 16 during installation, releasing
the adhesive so that this will permeate the interface
between the beam 16 and the foam layer 22.
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The tape 20 includes a zion-adhesive top layer ~4 disposed on
top of the foam material 22. The top layer 24 both facilitates
the unwinding of the tape 20 when it is rolled up (FIGS. 6A and
6B) and enables the builder to slide the panels 26, 66 of
wallboard or plywood (FIGS. 2-4-and 7-10, respectively) over the
top layer 24 during installation. This non-adhesive top layer 24
is preferably tough and slick so as to further facilitate the
sliding of the paneling 26 over the top layer 24 without damaging
the tape 20, 60. A suitable top layer 24 may be a thin (e.g. 1-4
mil) polyester liner such as a MylarT'" film which is mounted to
the underlying foam 22 with a thin layer of adhesive.
Alternatively, the non-adhesive top layer 24 may comprise a
release paper, or may be formed by heat sealing the upper surface
of the foam material 22 or creating a suitably smooth surface
integral to the foam material 22.
Since the non-adhesive top layer 24 contacts overlying
portions of the panels of wallboard 26 (FIGS. 1 and 2) and of
flooring 66 (FIG_ 8), it is understood that, for most
applications, it is not necessary for the tape 20, 60 to hold the
panels of wallboard 26 (FIG. 2) or flooring 66 (FIG. 8) in place.
In addition, because the top layer 24 is non-adhesive, personnel
can handle the beams 16, whether they be studs, joists or
rafters, after the insulating tape 20 has been laid thereon. In
the case of the joists 52 (FIGS. 7 and 8), personnel can even
walk about on top of the joists 52 where the tape 20, 60 has been
installed (see FIG. 11). Moreover, personnel can slide the panel
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26 over the top layer 24 anci i.Ilto pl.ac~w w:Ltl~out the panels 26, 66
catching on the tape 20, 60 and aamagi.ng ~t. Use of the tape 20,
60 also eliminates the problem of excessively quick set-up times
which are experienced with conventional glues. In addition, the
application of the tape 20, 60, as opposed to the application of
glue, can be separated in time from installation of the overlying
panels or can be done in small blocks of time. The tape 20, 60
is not affected by any inclement weather which may intervene
between the time of tape application and placement of the
overlying panels. In light of the above, use of the tape 20, 60
improves work efficiency since the construction with beams and
panels using the tape 20, 60 does not require large blocks of
time to be schedule; but rather can be accomplished at the ends
of working days or by intermittently spacing the work between
other projects.
c. Installation
FIGS. 6A and 6B illustrate two preferred methods by which,
in accordance with the present invention, the insulating tape 20
can be applied to a beam 116. The beam 116 may be a component of
any frame structure of a building constructed of beams, such as a
floor, wall, ceiling, or roof. The beam 116 thus may be a stud,
joist, or rafter.
In the method which is shown in FIG_ 6A, the tape 20 is
reverse wound on a roll or spool 32 so that the adhesive side 30
of the tape 20 faces outwardly therefrom. Consequently, as the
spool 32 is rolled along the underlying surface 119 of the beam
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;. ~e , the adhesive side 30 of the tape adheres to it so that the
tape 20 unrolls from the spool 32, leaving the non-adhesive side
24 exposed and facing upwardly from the beam 116.
FIG. 6A shows an operator 34 laying a strip of the tape 20
on the beam 116 prior to the beam 116 being installed into a
frame structure. This technique is particularly advantageous
wherever building conditions, project schedules, or other factors
render it preferable to lay the tape 20 on the beam 116 prior to
it being put into the building structure. To do this, the
operator places the beam 116 on a suitable support, such as saw
horses 38a, 38b, and then grasps the spool 32 and rolls it along
in the direction indicated by arrow 40 so as to lay the strip of
tape 20 on the upper edge 119 of the beam 116. The spool 32 has
a peripheral channel 33 formed between flanges 35. The channel
33 is sized to receive the edge 119 of the beam 116 and thus
helps to guide the spool 32 as it is rolled along the beam 116.
The beam 116 can then be lifted or otherwise transported to the
installation site.
FIG. 6B, in turn, shows a hand-operated tool 42 which can be
used to apply the adhesive insulating tape 20 in accordance with
another aspect of the present invention. The tool is similar to
that described in U.S. Patent No. 5,254,203. The tool 42
comprises a spool portion 44 which is mounted part way up along a
handle portion 46. The spool portion 44 is provided with a
central hub 48 which rotates about an axle 50 perpendicular to
the handle portion 46. The spool portion 44 contains a roll 32
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of the adhesive cushioning tape 20 which is wound with the
adhesive side facing inwardly.
Preferably, the handle portion 46 may be about 2' in length,
with a length of 22" being an excellent compromise in terms of
both handling ease and packaging convenience (when using standard
24" boxes). Tubular metal conduit of 3/4" has been found to be
eminently suitable for forming the handle 46, from the standpoint
of cost, weight, and ease of fabrication. The upper end of the
handle portion 46 is bent slightly rearwardly (e. g., about
10-20°) from the lower portion to provide a more horizontal
portion which can be conveniently held by a standing operator,
and this is preferably provided with a hand grip 52.
The lower end of the handle 46, in turn, is provided with an
adjustable guide roller assembly 54 which presses the tape 20
against the edge 55 of the beam 16 so that it firmly adheres to
the upper surface 119. The tape 20 is fed off the rearward side
of the spool and led downwardly and under the guide roller
assembly 54. Thus, as the tape 20 passes under the roller
assembly 54, it is pressed against the upper surface 119 of the
beam 116 by pressure which is exerted through the handle portion
46 of the tool 42 in the direction indicated by arrow 56.
The guide roller assembly 54 includes two compound sidewall
assemblies 58a, 58b which form a channel for receiving both the
upper surface 119 of the beam 116 and the strip of tape 20 which
is unrolled from the spool portion 44. Each of the compound
sidewalls 58a-b is made up of a plurality of plate-like elements,
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which are individually displaceable ire an :upward direction by
rotation about the axle of tive as ~emb.l.y 54 , so a:~ to be able to
adjust the channel width to match that of the upper surface 119
of the beam 116. The plate elements are then locked in place by
means of a wing nut 60 on the end of the axle. The guide roller
assembly also includes a cutter 62 which is employed to cut the
tape 20 after a predetermined amount, known as "a run" has been
laid on the upper surface 119 of the beam 116.
The techniques which have been described are particularly
suited to installation of the insulating tape 20 in a field
environment, such as a job site. There is, however, an
increasing trend towards factory fabrication of: the beams 16,
such as joists, studs, and rafters; pre-assembled frame
structures 23 tFIG. 2); and even complete walls, and other
modular building components. The present invention is suitable
for practice in such contexts as well. The beams 16, or even an
entire frame structure 23 (FIG. 2), may be delivered to the job
site ready to use, with the tape 20 already adhered to the edges
of the beams 16 or predetermined edges of the frame structure 23
as seen in FIGS. 2 and 7, respectively.
In addition, the tape 20 can be applied using high-speed
mechanized or automated systems in place of the manual approaches
described above. Such systems may include mechanized applicators
and rollers, and cartridge or continuous tape feed. Moreover,
such systems may include suitable computerized controls which may
be integrated with controls for the construction of the
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sr_r-uctura~ beam itself .
Still further, it may be advantageous in some embodiments to
dispense with the use of the tape 20 and apply the foam material
22 to the beams by other means, such as by depositing the
material on the edge 19 of the beam 16 in a fluid or semi-fluid
state, such as by a foamed-in-place system where the fluid
constituents react to produce a semi-solid foam end product. As
yet another alternate, instead of strips of the tape 20, the
material 22 can be placed on the beam 16 by cutting a strip
directly from a layer sheet of insulating material. It should
also be noted that many of these techniques, although
particularly adapted to factory operations, may find applications
in a field environment as well.
d. Flooring Systems
The present invention presents many advantages not only in
the construction of walls, but also in the construction of
floors, ceilings, roofs, and other frame structures, particularly
where these serve to separate areas of differing temperatures.
FIGS. 7-10 illustrate the present invention as applied to
construction of another type of frame structure, namely, a floor
50. Floor 50 includes a plurality of metal joists 52, which are
a particular type of the beams 16 described above with reference
to FIGS. 1 and 2. The joists 52 extend in a horizontal direction
with a planar load-bearing surface 54 facing in an upward
direction. Such metal joists 52 can be sized similar to their
conventional wooden counterparts (e. g., 2x12's), or may have much
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wider upper load-bearing surfaces (e.g., 31/4 inches wide or
more), the latter being commonly referred to in the industry as
"space joists." The joists 52 are arranged in generally
parallel, laterally spaced relation to each other and are
supported across their ends by a metal or wooden header 56. On
either side of the metal joists 52 are rim joists 57.
In this embodiment, the floor 50 includes insulating tape 60
in strips laid upon the upper, load-bearing surfaces 54 of the
metal joists 52. The tape 60 is formed using materials and a
structure similar or identical to the tape 20. However, the
width of the tape 60 may vary from the width of tape 20 since the
upper surface 54 of the joist 52 may be different from that of
the beams 16. So, for example, the tape 20 that is used on the
narrower beams 16, such as studs, may be narrower than the tape
60 which is used on wider beams, such as the joists 52. To
enhance both the effectiveness of the insulating tape 60 as
applied to the joists 52 and to provide a flat, continuous
surface for overlying subfloor panel 66, strips 62, 64 of the
tape 60 may preferably be laid on the upper edges of the headers
56 and the rim joists 57 as well.
After the strips of the tape 60 have been laid down, panels
66 of plywood or other subfloor panel material are placed on top
of the tape 20, as shown in FIG 8. The tough, slick,
non-adhesive covering 24 of the tape 66 permits the panels 66 to
be slid along and across surfaces of the joists 56 to the desired
position without damaging the tape 60. Also, workers can walk
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about on the joists 52 without damagirm~ t_iue re sil.ientl.y
compressible material 22 (FIG. 5) undez_neath t: he covering 24.
Preferably, as is shown in FIG. 9, the panels 66 are positioned
so that their edges meet over the load-bearing top surfaces 54 of
the joists 52 and are supported thereby. Since the panels 66 are
not glued to the joists 52, they can beg rearranged atop the
joists 52 for optimum fit.
Finally, as is shown in FIGS. 9 and 10, the panels 66 are
secured in place by means of fasteners 68, which are driven
through the panels 66 and into the upper- surfaces 54 of the
joists 52.
The tape 60 is sandwiched between the floor joists 52 and
the panels of subflooring 66. As discussed above with reference
to FIGS. 1 and 2, this layer provides thermal insulation between
the joists 52 and the panels 66. The tape 60, since it is made
of the foam material 22 (FIG. 5) which is resiliently
compressible, also acts to "smooth out" irregularities and
discontinuities in the surfaces 54 of'the joists 52 and the
overlying portions of the panels 66. In this way, the tape 60
eliminates gaps between the joists 52 and the panels 66, which
gaps would otherwise permit the panels 66 of subflooring to work
up and down against the fasteners 68 (FIG. 9) and cause squeaks.
e. Wood Construction
Although the present invention has been discussed with
reference to the metal joists 52, the invention also yields many
advantages in buildings having floors, walls, ceilings, and
21
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214fi(1~5
roofs, made of wooden beams.
For example, FIG. 11. sr:ow~~ a floor structure 142 having a
generally conventional foundation 144 which supports a series of
wooden floor joists 146 joined together at their ends by headers
S 148. For residential construction, the joists may typically be
2" x 12" boards or the like, laid on edge. The tape 147 is
composed of resiliently compressible material 22 described
previously with reference to the tape 20 (FIG. 5), and is shown
being installed using a tool 110. The tool 110 includes a handle
130 having a spool 112 similar to the spool 32 (FIG. 6B) mounted
to the lower end of the handle 130. The operator 140 unrolls a
bit of the tape 147 from the spool 112 and places it at the
desired point on the joist 146. The top of the joist 146 is then
slipped into the channel between the two flanges of the spool 142
so that the adhesive surface of the tape contacts and adheres to
the joist. Then, using the handle 130, the operator rolls the
spool 112 along the top of the joist 146 in the direction
indicated by arrow 50; as this is done, a strip of the tape 14?
unrolls from the spool 132 and adheres to the edge of the joist
146. If desired, the tape 147 can also be laid along the top of
the header 148 as shown in FIG. 12.
The panels 152 which make up the subfloor are then slid over
the top surfaces of the joists 146 and into place as described
previously with reference to FIGS. 7-10. The operator 140 is
able to walk about on the non-adhesive, upper surface of the tape
147 while moving the panels 152 into place. FIG. 14 shows a
22
CA 02146055 1995-05-17
~1~~~~~
cross-section through the flooring structure 142 having the
cushioning tape 147 installed on the wooden joists 146. The
uneven upper edge of the joists 146 (which may be due to warping
or bowing of the joists) produces discontinuities or gaps 156
between the joists 146 and the overlying panel of plywood 152,
which (if let unfilled) would allow the panel of plywood 152 to
flex up and down as people walked across it, resulting in squeaks
as the plywood rubbed against the shanks of nails 154. However,
since the tape 147 provides a resiliently compressible foam layer
when sandwiched between the panel 152 and the joist 146, the tape
147 fills the gaps 156 so as to prevent the plywood panel 152
from flexing downwardly by an appreciable distance under a
person's weight, thus eliminating the vertical movement of the
plywood panel 152 which could cause squeaking.
Furthermore, ring nails are a suitable type of fastener 154
used in the floor 142. When the ring nails are driven through
the tape 147, a portion of the foam material 22 is picked up in
the grooves along the shanks of the fasteners 154; in the
unlikely event that the panel 152 lifts beyond the ability of the
tape 147 to fill the resulting gap (as, for instance, if the
plywood bows due to becoming wet), the "lubricating" affect of
the foam material 22 which is retained on the shanks of the
fasteners 154 will serve as additional assurance against the
development of squeaks.
FIG. 12 shows the optional use of staples 198 to help hold
the strips of the adhesive tape 147 on the upper edges of the
23
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21~60~
joists 146. This may be desirable when condit:i.ons are so wet
that the adhesive of the tape 147 alone' has difficulty holding to
the joist 146, especially when people are walking or sliding the
panels of .plywood 152 over the adhesive tape 147. However, it
will be appreciated that using the staples 198 to hold the tape
147 in place is only necessary as a supplemental measure, and
once the joists 146 are dry, the adhesive of the tape 147
preferably will adhere to the joists 146 so as to permanently
hold the tape 147 in position.
FIG. 13 illustrates the use of the present invention in the
construction of a vertically extending wall structure 200
constructed using wooden studs 202. Apart from its vertical
orientation, the configuration of this construction is similar to
the floor structure 142 seen in FiG. 11. Strips of adhesive tape
204 formed of resiliently compressible, thermally insulating,
foam material are laid on the edges of the studs 202 (using
techniques substantially similar to those described above), and
then a suitable panel 206, such as wall covering, plywood or
panel rock, is installed over the studs 202 using nails 208 or
other suitable fasteners.
In frame structures such as the vertically extending wall
structure 200, it is possible to provide the outwardly facing
surface of the tape 204 with a certain degree of adhesiveness or
"tackiness" which helps hold the panel 206 against the tape 204
and the studs 202. Typically, the panel 206 is mounted to the
studs 202 by fasteners 208, such as screws, installed using an
24
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214605
automatic screwdriver. ~s the Tasteners 208 are installed, the
resiliently compressible foam material of the tape 204 is
partially compressE~d as discussed previously to provide a
"filler" for any gaps that might otherwise occur between the
S paneling 206 and the studs 202, while still providing thermal
insulation between the two.
Having described the invention in its preferred embodiments,
it will be clear that numerous changes and modifications may be
made without departing from the spirit of the invention. It is
therefore not intended that the words used to describe the
invention or the drawings illustrating the same be limiting on
the invention, but rather that the invention be limited only by
the scope of the appended claims.
