Title:
Panel mounting system for high temperature applications
Kind Code:
A1


Abstract:
An insulation finishing system includes a plurality of lineals fixed to a building structure. The lineals include lineal partitions which protrude from the building structure and which define primary insulation cavities. A plurality of primary insulation panels are positioned within the primary insulation cavities. A plurality of trim pieces fix the primary insulation panels within the primary insulation cavities. The primary insulation panels are provided with an interference fit with the lineal partitions.



Inventors:
Weir, Charles R. (Westerville, OH, US)
Brokaw, Matthew C. (Bellville, OH, US)
Application Number:
11/582117
Publication Date:
03/29/2007
Filing Date:
10/17/2006
Primary Class:
International Classes:
E04B1/74
View Patent Images:
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Primary Examiner:
GILBERT, WILLIAM V
Attorney, Agent or Firm:
OWENS CORNING (GRANVILLE, OH, US)
Claims:
What is claimed is:

1. An insulation finishing system comprising: a plurality of lineals fixed to a building structure, the lineals including a lineal partition which protrudes from the building structure, wherein the lineal partitions define primary insulation cavities; a plurality of primary insulation panels positioned within the primary insulation cavities; and a plurality of trim pieces connected to the lineals, the trim pieces fixing the primary insulation panels in the primary insulation cavities; wherein the primary insulation panels within the primary insulation cavities are provided with an interference fit with the lineal partitions.

2. The insulation finishing system of claim 1, wherein the interference fit is in a horizontal direction.

3. The insulation finishing system of claim 1, wherein the trim pieces are resistant to heat up to a temperature of 260° F.

4. The insulation finishing system of claim 1, wherein the trim pieces are releasably connected to the lineals.

5. The insulation finishing system of claim 1, wherein the primary insulation panels maintain their position within the primary insulation cavities when subjected to the 300° F. Air Temperature Exposure Test under the Standard Building Code (SBC—Section 893.9.4) and Uniform Building Code (UBC—Section 802.1).

6. The insulation finishing system of claim 1, wherein the primary insulation panels maintain their position within the primary insulation cavities when subjected to the 300° F. Air Temperature Exposure Test under the Standard Building Code (SBC—Section 893.9.4) and Uniform Building Code (UBC—Section 802.1), and a comparable system without the interference fit fails to maintain the position of the panels under said test.

7. The insulation finishing system of claim 1, wherein the primary insulation panel is compressible so that the insulation panel can be placed with an interference fit in the insulation cavity.

8. The insulation finishing system of claim 1, wherein a plurality of lineal adaptors are connected to the lineals, the lineal adaptors including adaptor partitions which protrude from the lineals, the adaptor partitions defining secondary insulation cavities; wherein finish insulation panels are positioned within the secondary insulation cavities, wherein the plurality of trim pieces are connected to the lineal adaptors, the trim pieces fixing the finish insulation panels in the secondary insulation cavities, wherein the finish insulation panels within the secondary insulation cavities are provided with an interference fit with the adapter partitions

9. The insulation finishing system of claim 8, wherein the interference fit of the secondary insulation panels with the adaptor partitions is in a horizontal direction.

10. The insulation finishing system of claim 8, wherein the trim piece is resistant to heat up to a temperature of 260° F.

11. The insulation finishing system of claim 8, wherein the lineal adaptor is releasably connected to the lineal.

12. The insulation finishing system of claim 8, further including a vapor retarder between the primary insulation panel and the finish insulation panel.

13. The insulation finishing system of claim 8, wherein the primary insulation panel has a first thickness and the finish insulation panel has a second, different thickness.

14. A method of finishing a building structure which includes the steps of: attaching a lineal to the building structure, the lineal including a lineal partition which protrudes from the building structure to create an initial primary insulation cavity; positioning a primary insulation panel against the lineal partition using pressure to effect an interference fit with the lineal partition; positioning a subsequent lineal against the positioned primary insulation panel to effect another interference fit between the positioned primary insulation panel and the subsequent lineal partition; attaching the subsequent lineal to the building structure; and connecting trim pieces to the lineals thereby fixing the primary insulation panels within the primary insulation cavities with an interference fit.

15. The method of claim 14, wherein the pressure is hand applied.

16. The method of claim 13, wherein the interference fit is in a horizontal direction.

17. A method of finishing a building structure which includes the steps of: attaching a first lineal to the building structure, attaching a second lineal to the building structure at a distance from the first lineal to create an initial primary insulation cavity of a desired width; positioning a primary insulation panel between the lineal partitions using pressure to effect an interference fit with the lineal partitions; and connecting trim pieces to the lineals thereby fixing the primary insulation panel within the primary insulation cavity with an interference fit.

18. The method of claim 17, wherein the desired width is established by determining the width of the panel to be installed between the lineals and establishing the desired width as being less than a width of the panel to be installed in the cavity.

19. The method of claim 17, wherein the desired width is established by positioning the second lineal at a distance which is less than a width of the panel to be installed, and thereafter cutting the panel to a width that is greater than the desired width.

20. The method of claim 17, wherein the primary insulation panel maintains its position within the primary insulation cavities when subjected to the 300° F. Air Temperature Exposure Test under the Standard Building Code (SBC—Section 893.9.4) and Uniform Building Code (UBC—Section 802.1), and a comparable system without an interference fit fail to maintain the panel's position under said test.

Description:

RELATED APPLICATIONS

This application is a continuation-in-part of co-pending application, U.S. Ser. No. 11/008,060 filed Dec. 09, 2004 which is incorporated by reference in its entirety. This application is also related to commonly assigned U.S. patent application entitled “Panel Mounting System For Reaction-To-Fire Test Applications”, filed on the same date, which is incorporated herein by reference.

TECHNICAL FIELD

The present invention relates generally to an insulated panel mounting system for building structures and, more particularly, to insulative panels which maintain their mounted position when exposed to high temperatures.

BACKGROUND OF THE INVENTION

Homeowners and businesses often desire to finish rooms, such as basements or above-ground rooms, in a manner which provides a comfortable and aesthetically pleasing atmosphere.

Most basements are constructed of common methods including cinder block walls or poured concrete walls. Left unfinished, cinder block or poured concrete basement walls can allow humidity into the basement, and also allow the loss of heat through the basement walls. Traditionally, basement walls have been finished by known methods including attachment of wood studs to the basement walls and subsequent attachment of a wall surface, such as drywall or paneling, to the wood studs. Insulation such as glass fiber insulation batts have been placed between the basement wall and the wall surface before attachment of the wall surface to the wood studs, or a granular or loose-fill fibrous insulation is poured or blown into the spaces between the basement wall and the wall surface after the wall surface is attached to the wood studs.

A known method of finishing a room involves the use of insulative panels releaseably connected to installed frame members as developed by the assignee herein, Owens Corning, and as described in the Weir et al. U.S. Pub. No. 2004/0219853 A1 for a “Room Finishing System”, and the Hettler et al. US Pub. No. 2005/0150183 A1 for an “Insulation System with Variable Position Vapor Barrier” which are expressly incorporated herein by reference.

It would be advantageous if the insulative panels were better capable of maintaining their mounted position within the frame members when the insulation finishing system is exposed to a high temperature exposure test.

SUMMARY OF THE INVENTION

An insulation finishing system includes a plurality of lineals fixed to a building structure. The lineals include lineal partitions which protrude from the building structure and which define primary insulation cavities. A plurality of primary insulation panels are positioned within the primary insulation cavities. A plurality of trim pieces fix the primary insulation panels within the primary insulation cavities. The primary insulation panels are provided with an interference fit with the lineal partitions.

According to this invention there is also provided a method of finishing a building structure. The method includes attaching a lineal to the building structure, the lineal including a lineal partition which protrudes from the building structure to create an initial primary insulation cavity, positioning a primary insulation panel against the lineal partition using hand applied pressure to effect an interference fit with the lineal partition, positioning a subsequent lineal against the positioned primary insulation panel to effect another interference fit between the positioned primary insulation panel and the subsequent lineal partition, attaching the subsequent lineal to the building structure; and connecting trim pieces to the lineals thereby fixing the primary insulation panels within the primary insulation cavities with an interference fit.

According to this invention there is also provided a method of finishing a building structure, according to the preceding paragraph, the method further including attaching an adapter to a lineal, the adapter including an adapter partition which protrudes from the lineal partition to create an initial secondary insulation cavity, positioning a finish insulation panel against the adapter partition using hand applied pressure to effect an interference fit with the adapter partition, positioning a subsequent adapter against the positioned finish insulation panel to effect an interference fit between the positioned finish insulation panel and the subsequent adapter partition, attaching the subsequent adapter to the lineal and connecting trim pieces to the adapters thereby fixing the finish insulation panels within the secondary insulation cavities with an interference fit.

Various objects and advantages will become apparent to those skilled in the art from the following detailed description of the various embodiments, when read in light of the accompanying drawings. It is to be expressly understood, however, that the drawings are for illustrative purposes and are not to be construed as defining the limits of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view, partially broken away, of a finishing system.

FIG. 2 is a cross-sectional view of a lineal and a trim piece for a finishing system.

FIG. 3 is a cross-sectional view of a finishing system taken along the line 3-3 in FIG. 1.

FIG. 4 is a cross-sectional view of a lineal, adapter and trim piece for a second embodiment of the finishing system.

FIG. 5 is a cross-sectional view of the second embodiment of the finishing system.

DETAILED DESCRIPTION AND PREFERRED EMBODIMENTS

The description and drawings disclose an insulation finishing system 10 for finishing a room. With reference to FIG. 1, an insulation finishing system 10 is shown installed on a building structure 12. For ease of explanation herein the building structure 12 will be generally referred to as a wall 12; however, it is to be understood that it is within the contemplated scope of the present invention that the building structure can include ceilings and other building structures. The wall 12 may be any type that one might desire to finish, either in a residential or a commercial building. The room may include more than one wall and may also include a floor (not shown) and a ceiling (not shown). The wall 12 may have windows and doors therein, (not shown).

The insulation finishing system 10 includes a plurality of lineals 20 which create primary insulation cavities 16, as shown in FIG. 3, when installed on the wall 12. As shown in FIG. 1, the lineals 20 are preferably made from a plastic material, but the lineals 20 can be made of metal or any other material suitable to be installed on a wall 12 and create primary insulation cavities 16.

The lineals 20 attach to the wall 12 in a suitable manner. In certain embodiments, the lineal 20 is attached to the wall 12 with suitable fasteners 14; however, in other embodiments, the lineal 20 can be affixed to the wall 12 with a suitable adhesive material or any other mechanism which provides attachment to the wall 12. or embedded into the wall, such as within a poured concrete wall.

The insulation finishing system 10 further includes primary insulation panels 50. The primary insulation panel 50 may be made of any type of insulation known to those of skill in the art, such as, but not limited to, fiberglass insulation, a fiberglass board, rock wool board, polymer or natural fiber board, mineral board, or a foam board. Typical densities of the fibrous insulation panels 50 will be in the range from about 2 to 15 pounds per cubic foot (pcf), although other densities can be used. The foam may be formed of extruded polystyrene, molded polystyrene, polyisocyanurate, phenolic foam, polyurethane, or other similar foam insulation products.

In certain embodiments, if a fibrous insulation board is used, a board that can be used is a 700 Series glass fiber insulation board available from Owens Corning. In particular, a 703 Series board having a density of at least about 3 lb/ft3 can be used. Such glass fiber insulation boards are composed of glass fibers having a binder thereon which has been cured to bind the fibers into a matrix. For densities above about 2.25 lb/ft3, boards of such bindered glass fibers are relatively rigid, meaning that they generally support their own weight when stood on their end and do not sag by any significant amount when left in such a position for a long period of time.

The primary insulation panels 50 include a decorative facing 54 attached to the outer surface of the primary insulation panel 50, as best shown in FIG. 3. In most cases, the decorative facing provides an aesthetically pleasing and durable cover for the primary insulation panel 50. The facing 54 can be any type of decorative covering, such as fabric or vinyl, suitable to provide an aesthetically pleasing and durable cover for the primary insulation panel 50.

The primary insulation panels 50 may be applied in a step-wise fashion until the wall 12 is covered by the primary insulation panels 50, as will be further explained below.

As best shown in FIG. 2, the lineal 20 has a lineal base plate 22 which has opposing lineal retaining flanges 22a and 22b. The lineal 20 also has opposing lineal partitions 24 and 25 which extend from the lineal base plate 22. In certain embodiments, the use of lineal partitions 24, 25 additionally helps to reduce the overall cross sectional area of the direct paths of thermal conduction between the wall 12 and the interior of the room, and thus to improve the overall R value of the finished system.

The opposing lineal partitions 24 and 25 define a receiving channel 26 for engaging the trim piece 40, as will be further explained below. In certain embodiments, the lineal partitions 24 and 25 allow a releasable engaging connection to be formed between the lineal 20 and the trim piece 40.

In certain embodiments, one or more of the lineal partitions members 24, 25 can include one or more inwardly extending detents 28a, 28b for securing the trim piece 40 in the lineal 20. The lineal base plate 22 can include at least one break-away notch 29 that extends along the intersection of the lineal base retaining flange 22a and the lineal partition 24. The break-away notch 29 allows the installer to easily remove the lineal base retaining flange 22a so that the lineal 20 can be installed in a corner or other area such as against a window or door (not shown).

The insulation finishing system 10 also includes a plurality of trim pieces 40 which connect to the lineals 20 and retain the primary insulation panels 50 within the primary insulation cavity 16. As shown in FIG. 1, the trim pieces 40 are preferably made from a plastic material, but the trim pieces 40 can be made of metal or any other material suitable to connect to the lineals 20 and retain the primary insulation panels 50 within the primary insulation cavities 16.

The trim piece 40 has a trim base plate 42 with opposing trim retaining flanges 42a and 42b. The trim piece 40 can have an outer surface 44 preferably treated in a manner well-known in the art such that the outer surface 44 presents a decorative finish, such as simulated wood grain finish.

The trim piece 40 also has a trim connector 43 which extends from a bottom of the trim base plate 42. The trim connector 43 can have any desired shape so that the trim connector member 43 can fit within the receiving channel 26 of the lineal 20 or otherwise attach to the lineals. In the embodiment shown in FIG. 2, a preferred trim connector 43 has generally convex walls 43a and 43b.

In general, the trim retaining flanges 42a and 42b maintain the primary insulation panel 50 in the primary insulation cavity 16 and provide a decorative interface between adjacent primary insulation panels 50. In certain embodiments, as shown in FIG. 1, a trim piece 40 can be oriented in a vertical direction and used as a vertical divider member 40′, which is inserted between adjacent insulation panels 50 and 50′.

During the installation process, the insulation finishing system 10 may be installed in a step-wise fashion until the wall 12 is covered. An initial lineal 20 is fixed to a wall 12, thereby forming an initial primary insulation cavity 16. An initial primary insulation panel 50 is positioned in the initial primary insulation cavity 16, such that the end portion 51 of the initial primary insulation panel 50 is pressed against the lineal partition 24 preferably using hand applied pressure. Preferably only hand applied pressure is necessary to effect an interference fit between the end portion 51 of the primary insulation panel 50 and the lineal partition 24. Following installation of the primary insulation panel 50, a subsequent lineal 20 is pressed against the installed primary insulation panel 50, again using only hand pressure, and the subsequent lineal 20 is fastened to the wall 12 using appropriate fasteners 14. This procedure is followed until the wall 12 is covered by the primary insulation panels 50. In certain installations, a temporary clip, such as a scrap part of a lineal 20 and/or trim piece 40, can be used to hold the primary insulation panel 50 within the primary insulation cavity 16 during the sequential installation of subsequent insulation panels 50.

In a certain embodiment, the interference fit between the primary insulation panels 50 and the lineal partitions 24, 25 is in the horizontal direction α, as shown in FIG. 1. Alternatively, the interference fit between the primary insulation panels 50 and the lineal partitions 24, 25 may be in a vertical direction or may be simultaneously in both a horizontal and vertical direction.

As shown in FIG. 3, the trim retaining flanges 42a and 42b extend outwardly such that, when the insulation finishing system 10 is assembled, the primary insulation panel 50 is located within the primary insulation cavity 16. Thus, the base plate 42, with its flanges 42a, 42b, on the trim piece 40, holds (or retains) the primary insulation panel 50 within the primary insulation cavity 16.

In certain embodiments, the primary insulation panel 50 has a certain thickness. It is to be understood that the R-values of the primary insulation panel 50 may be determined for a particular geographic region.

As shown in FIG. 3, the primary insulation panel 50 is positioned within the primary insulation cavity 16 so that there is an interference fit between the end portion 51 of the primary insulation panel 50 and the lineal partitions 24, 25. An interference fit is defined as constant direct contact between the end portion 51 of the primary insulation panel 50 and the lineal partition 24, 25 such that there is substantially no continuous gap or clearance between the end portion 51 of the primary insulation panel 50 and the lineal partition 24, 25. The interference fit between the end portion 51 of the primary insulation panel 50 and the lineal partition 24, 25 must provide enough contact to prevent hot gases from flowing along the lineal partition 24, 25 to the lineal 20. The interference fit between the end portion 51 of the primary insulation panel 50 and lineal partition 24 is achieved during the installation of the primary insulation panels 50 by hand applied pressure applied to the primary insulation panels 50 and also applied to the subsequently installed lineals 20. This procedure has the advantages of eliminating the installation steps of sizing, measuring and cutting the primary insulation panels 50. But, an interference fit between the end portion 51 of the primary insulation panels 50 and the lineal partitions 24, 25 can also be made by the installation steps of sizing, measuring and cutting the primary insulation panels 50, or by installing the lineal partitions 24 spaced a distance apart based on the width of the insulation panels 50 so as to create a cavity with a width which creates the desired interference fit.

The interference fit between the primary insulation panels 50 and the lineal partitions 24, 25 is a key element in allowing the insulation finishing system 10 to resist heat when the insulation finishing system 10 is exposed to high temperatures, such as in heat exposure testing. Resisting heat is defined to mean a period of time, at a defined temperature, before the component softens so as to become unusable for its intended purpose. Heat exposure tests, such the 300° F. Air Temperature Exposure Test under the Standard Building Code (SBC—Section 893.9.4) and Uniform Building Code (UBC—Section 802.1), require that the primary insulation panels 50 will not become detached when subjected to a room temperature of 300° F. for 30 minutes. Most removable panel systems include the use of plastic polymer components, such as brackets and trim pieces, which soften when exposed to temperatures over 240° F. Some plastic polymer components can even resist temperatures up to 250-260° F. through the use of chemical additives, although even these components will typically soften at temperatures above 260° F. The plastic polymer components can be directly exposed to heated air if there are gaps between the components and the insulation panels. This can hasten the softening of the components. Softening of the plastic polymer components allows the removable panels to fall from their mounted positions, thereby failing a heat exposure test. The insulation finishing system 10 overcomes these problems through the interference fit of the primary insulation panels 50 and the lineal partitions 24, 25 as well as through preventing heated air from moving through the lineal 20. Specifically, the interference fit between the end portions 51 of the primary insulation panels 50 and the lineal partitions 24, 25 prevents gaps, thereby preventing heated air from flowing along the lineal partitions 24, 25. The interference fit thereby insulates the lineals 20 from the heated air. By insulating the lineals 20 from the heated air, the interference fit of the primary insulation panel 50 and the lineal partition 24, 25, prolongs the time before the lineal 20 softens due to the heat exposure and therefore allows the primary insulation panels 50 to maintain their installed position on the wall 12 during the heat exposure test.

Additionally, as previously discussed, the trim piece 40 includes a trim connector 43 that is configured to fit within the receiving channel 26 of the lineal 20. The trim piece 40 is another important element in allowing the insulation finishing system 10 to maintain the position of the primary insulation panels 50 when the system 10 is exposed to high temperatures during the heat exposure test. Specifically, the trim connector 43 prevents heated air from entering the receiving channel 26, thereby insulating the lineal 20. By insulating the lineals 20 from the heated air, the trim piece 40 prolongs the time before the lineal 20 softens due to the heat exposure and therefore allows the primary insulation panels 50 to maintain their installed position on the wall 12 during the heat exposure test.

In summary, the insulation finishing system 10 includes an interference fit between the end portion 51 of the primary insulation panels 50 and the lineal partitions 24, 25 within the insulation cavity 16. The interference fit, which when combined with the insulating properties of the trim piece 40, ensures that the lineals 20 will resist softening due to heat exposure longer than would otherwise be the case, and the primary insulation panels 50 will maintain their installed positions when the insulation finishing system 10 is exposed to high temperatures during heat exposure testing.

In another embodiment, the insulation finishing system 10 includes lineal adaptors 30 that create secondary insulation cavities 18, as shown in FIGS. 4 & 5, when connected to the lineals 20. As shown in FIGS. 4 & 5, the lineal adaptors 30 are a plastic material, but the lineal adaptors 30 can be made of metal or any other material suitable to be connected to the lineals 20 and create secondary insulation cavities 18.

As shown in FIG. 4, the lineal adaptor 30 has opposing adaptor partitions 34 and 35 which extend from a top side of the adaptor base plate 32. The opposing adaptor partitions 34 and 35 define an adapter receiving channel 36 for engaging the trim piece 40, as will be explained below. In certain embodiments, the adaptor partitions 34, 35 allow a releasable engaging connection to be formed between the lineal adaptor 30 and the trim piece 40.

FIG. 4 also shows the lineal adaptor 30 including an adaptor base plate 32 with opposing adaptor retaining flanges 32a and 32b. The lineal adaptor 30 also has a connector member 33 which extends from a bottom side of the adaptor base plate 32. The connector member 33 can have any desired shape so that the connector member 33 can fit within the lineal receiving channel 26. In the embodiment shown, the connector member 33 has generally convex walls 33a and 33b.

Referring again to FIG. 5, each lineal adaptor flange 32a and 32b extends outwardly such that, when the insulation finishing system 10 is assembled, the primary insulation panel 50 is located within the primary insulation cavity 16. Thus, the base plate 32, and its flanges 32a, 32b, on the lineal adaptor 30, holds (or retains) the primary insulation panel 50 within the primary insulation cavity 16.

In certain embodiments, one or more of the adaptor partitions 34, 35 can include one or more inwardly extending detents 38a, 38b for securing the trim piece 40 to the lineal adaptor 30. The adaptor base plate 32 can include at least one break-away notch 39 that extends along the intersection of the adaptor base retaining flange 32a and the adapter partition 34. The break-away notch 39 allows the installer to easily remove the adaptor retaining flange 32a so that the lineal adaptor 30 can be installed in a corner or other area such as against a window or door (not shown).

When the lineal adaptor 30 is connected to the lineal 20, the adaptor connector 33 is positioned within the lineal receiving channel 26 of the lineal 20. In certain embodiments, the adaptor connector 33 snaps into the lineal partitions 24, 25 such that the adaptor connector 33 releasably retains the lineal adaptor 30 in engagement with the lineal 20. For example, the lineal adaptor 30 can be snapped into the lineal 20 such that, if necessary, the lineal adaptor 30 can be removed without damage to the lineal 20 or the lineal adaptor 30 itself. It is to be understood, that in another embodiment, the releasable connection between the lineal 20 and the lineal adaptor 30 can be achieved by a fast-release or other type of connector. Additionally, the lineal partitions 34 and 35 allow a releasable connection to be formed between the lineal adaptor 30 and the trim piece 40.

The insulation finishing system 10 further includes a plurality of finish insulation panels 70 having a decorative facing 74 attached to an outer surface of the finish insulation panels 70. When installed, the finish insulation panel 70 is located in the secondary insulation cavity 18.

The finish insulation panels 70 may be made of any type insulation known to those of skill in the art, such as, but not limited to, fiberglass insulation, a fiberglass board, rock wool board, mineral board or a foam board. Typical densities of the finish insulation panels 70 will be in the range from about 2 to 15 pounds per cubic foot (pcf), although other densities can be used. The foam board may be formed of extruded polystyrene, molded polystyrene, polyisocyanurate, phenolic foam, polyurethane, or other similar foam insulation products identified by one of skill in the art.

The decorative facing 74 can be any type of decorative covering, such as fabric or vinyl, suitable to provide an aesthetically pleasing and durable cover for the finish insulation panels 70.

In certain embodiments, a vapor retarder 60 is positioned near or adjacent to the primary insulation panel 50 after a plurality of the primary insulation panels 50 are positioned in the primary insulation cavity 16. The vapor retarder 60 may be a sheet of plastic film (e.g., polyethylene, nylon, or a rubber membrane (EPDM)) or a foil (e.g., aluminum foil)) having a low vapor permeance or other known vapor retarder material. When installed, as shown FIG. 5, a first portion 62 of the vapor retarder 60 is secured within the receiving channel 26 of the lineal 20, as explained below. A second portion 64 is positioned close to, or in certain embodiments, against, the primary insulation panel 50.

The vapor retarder 60 is placed over the primary insulation panel 50 and the lineal 20. In certain embodiments, the vapor retarder 60 is at least slightly stretched during the installation process. In a similar manner, to that explained above with respect to the primary insulation panels 50, the vapor retarder 60 can be held in place by the temporary clip/scrap section while the rest of the vapor retarder 60 is installed.

The lineal adaptors 30 are then connected to the lineals 20 such that the adaptor connector 33 inserts the first portion 62 of the vapor retarder 60 into the receiving channel 26 of the lineal 20, as best seen in FIG. 5.

The finish insulation panels 70 are placed into the secondary insulation cavities 18. In a similar manner with respect to the installation of the primary insulation panels 50, a part of a lineal adaptor and/or trim piece can be used to hold the finish insulation panel 70 within the secondary insulation cavity 18 during the sequential installation of the rest of the finish insulation panels 70. The trim pieces 40 are then attached to the lineal adaptors 30 to complete the insulation finishing system 10. The lineal adaptors 30 allow the vapor retarder 60 to be easily removed without damage, if necessary, by unsnapping the lineal adaptor 30 from the lineal 20.

In certain embodiments, the primary insulation panel 50 has a first thickness and the finish insulation panel 70 has a second, different thickness. It is to be understood that the R-values of the primary insulation panel 50 and the finish insulation panel 70 may be determined for a particular geographic region.

In a similar manner as discussed earlier with respect to the primary insulation panels 50, the finish insulation panels 70 are installed in a step-wise fashion until the primary insulation panels 50 are covered. An initial lineal adaptor 30 is connected to a lineal 20, thereby forming an initial secondary insulation cavity 18. An initial finish insulation panel 70 is positioned in the initial secondary insulation cavity 18, such that the end portion 71 of the initial finish insulation panel 70 is pressed against the adaptor partition 34 using hand applied pressure. Only hand applied pressure is necessary to affect an interference fit between the end portion 71 of the finish insulation panel 70 and the adaptor partition 34. Following installation of the initial finish insulation panel 70, a subsequent lineal adaptor 30 is pressed against the installed finish insulation panel 70, again using only hand pressure, and the adaptor connector 33 is connected to an installed lineal 20. This procedure is followed until the primary insulation panels 50 are covered by the finish insulation panels 70. In certain installations, a temporary clip, such as a scrap of a lineal 20 and/or trim piece 40, can be used to hold the finish insulation panels 70 within the secondary insulation cavities 18 during the sequential installation of the subsequent finish insulation panels 70.

In a certain embodiment, the interference fit between the finish insulation panels 70 and the adapter partitions 34, 35 is in the horizontal direction, as shown in FIG. 5. Alternatively, the interference fit between the finish insulation panels 70 and the adapter partitions 34, 35 may be in a vertical direction or may be simultaneously in both a horizontal and vertical direction.

As shown in FIG. 5, the trim retaining flanges 42a and 42b extend outwardly such that, when the insulation finishing system 10 is assembled, the finish insulation panels 70 are located within the secondary insulation cavity 18. Thus, the base plate 42, with its flanges 42a, 42b, on the trim piece 40, holds (or retains) the finish insulation panel 70 within the secondary insulation cavity 18.

As shown in FIG. 5 the finish insulation panels 70 are positioned within the secondary insulation cavity 18 so that there is an interference fit between the end portion 71 of the finish insulation panel 70 and the adaptor partitions 34, 35. As discussed earlier, an interference fit is defined as constant direct contact between the end portions 71 of the finish insulation panels 70 and the adapter partitions 34, 35 such that there is substantially no continuous gap or clearance between the end portion 71 of the finish insulation panels 70 and the partition adapters 34, 35. The interference fit between the end portions 71 of the finish insulation panels 70 and the adapter partitions 34, 35 must provide enough contact to prevent hot gases from flowing along the adapter partitions 34, 35 to the lineals 20. The interference fit between the end portions 71 of the finish insulation panels 50 and the adapter partitions 34, 35 is achieved during the installation of the finish insulation panels 70 by hand applied pressure applied to the finish insulation panels 70 and also applied to the subsequently installed lineal adapters 30. This procedure has the advantages of eliminating the installation steps of sizing, measuring and cutting the finish insulation panels 70. But, an interference fit between the end portions 71 of the finish insulation panels 70 and the adapter partitions 34, 35 can also be made by the installation steps of sizing, measuring and cutting the finish insulation panels 70. In such an instance, the width of the cavity 18 is less than the width of the panel 70. The degree of interference is adequate to enable passage of the heat exposure testes, and may differ based on the density of the board, the materials of the board, or the nature of the edge of the board and/or the trim pieces. In some instances, an interference of 0.005″ or less may suffice, and in other instances, an interference fit of 0.125, 0.25, 0.375 or 0.5 inches or more may be necessary, but this is determined based on the nature of the overall system. Additionally, it may be advantageous to provide projections extending from the edge of the lineals to engage the panels 70 to improve the interference fit.

The interference fit between the finish insulation panels 70 and the adapter partitions 34, 35 is another key element in allowing the insulation finishing system 10 to resist heat when the insulation finishing system 10 is exposed to high temperatures, such as in heat exposure testing. As discussed previously, resisting heat is defined to mean a period of time, at a defined temperature, before the component softens so as to be unusable for its intended purpose. The insulation finishing system 10 provides heat resistance through the interference fit of the end portions 71 of the finish insulation panels 70 and the adapter partitions 34, 35 as well as through preventing heated air from moving through the adapter 30 to the lineal 20. Specifically, the interference fit between the end portions 71 of the finish insulation panels 70 and the adapter partitions 34, 35 prevents gaps, thereby preventing heated air from flowing along the adapter partitions 34, 35 to the lineals 20. The interference fit thereby insulates the adapters 30 and the lineals 20 from the heated air. By insulating the adapters 30 and the lineals 20 from the heated air, the interference fit of the end portions 71 and the finish insulation panels 70 and the adapter partitions 34, 35, prolongs the time before the adapters 30 and the lineal 20 soften due to the heat exposure and therefore allows the primary insulation panels 50 and the finish insulation panels 70 to maintain their installed position on the wall 12 during the heat exposure test.

Additionally, as previously discussed, the trim piece 40 includes a trim connector 43 that is configured to fit within the receiving channel 36 of the adapter 30. The trim piece 40 is another important element in allowing the insulation finishing system 10 to maintain the position of the primary insulation panels 50 and the finish insulation panels 70 when the system 10 is exposed to high temperatures during the heat exposure test. Specifically, the trim connector 43 prevents heated air from entering the receiving channel 36 of the adapter 30, thereby insulating the adapters 30 and the lineals 20. By insulating the adapters 30 and the lineals 20 from the heated air, the trim piece 40 prolongs the time before the lineals 20 soften due to the heat exposure and therefore allows the primary insulation panels 50 and the finish insulation panels 70 to maintain their installed position on the wall 12 during the heat exposure test.

While the invention has been described with reference to a preferred embodiment, it should be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the essential scope of the invention. In addition, many modifications may be made to adapt a particular situation or panel to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims.





 
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