BUILDING INSULATIONS, BUILDING INSULATION SYSTEMS AND RELATED METHODS

Abstract

Building insulations, building insulations systems, and related methods are provided. A building insulation can include an insulation body having a bottom surface and a top surface. The insulation body can be configured to reduce conduction of heat through the insulation body. The building insulation can include a facing secured to the bottom surface of the insulation body. Further, the building insulation can include a plurality of reinforcing straps secured between the facing and the bottom surface of the insulation body. The reinforcing straps is spaced apart from one another and provide reinforcing strength for attachment of the building insulation to a building.

Description

TECHNICAL FIELD

The present subject matter relates to building insulations, building insulations systems, and related methods. Broadly, the present subject matter relates to insulation products and systems that can be attached to a roof support, such as an eave strut of a building and then to the underside of each purlin of the building. In particular, the present subject matter relates to thermal insulations, thermal insulation systems, and methods of installation that provide a continuous thermal barrier for the inside of the building and provide built-in weight reinforcements to facilitate the support of the thermal insulation when hung from a roof support of a building.

BACKGROUND

Steel building insulation materials are designed to improve the insulation of a building while reducing thermal energy or heat loss. The goal of installing insulation of reducing thermal energy or heat loss can be measured based on R-values. R-values can measure the capacity of an insulating material to resist heat flow with a higher R-value indicating greater insulating power. Different states can have different suggested or required R-values for insulation that is to be installed in residential and commercial buildings.

Fiberglass (or fiber glass) insulation body—which consists of extremely fine glass fibers—is one of the most ubiquitous insulation materials. It's commonly used in different types of insulation, including blankets of insulation (batts and rolls), loose-fill insulation and can also be available as rigid boards and duct insulation.

Fiberglass loose-fill insulation is made from molten glass that is spun or blown into fibers; Most manufacturers use 20% to 30% recycled glass content. Loose-fill insulation must be applied using an insulation-blowing machine in either open-blow applications (such as attic spaces) or closed-cavity applications (such as those found inside walls or covered attic floors). Batts of fiberglass can be formed by glass being spun or blown into fibers into a fleecy mass with binders added to for the batts. A thermal facing can be added to the insulating fiberglass material batts to form the insulation. Facing materials that are applied to the insulating fiberglass batts can serve as a protective cover over the fiberglass insulation. Facing materials can offer a clean finished look to any metal building environment.

Facings are fastened to insulation materials during the manufacturing process. A facing can protect the insulation's surface, can hold the insulation together, and can facilitate fastening to building components. Some types of facing can also act as an air barrier, and/or vapor barrier. The climate in which the building resides can help in the determination of what type of facing should be use.

Most commonly used thermal insulation only protect against one aspect of heat transfer—conduction. Expensive foam products can protect against conduction and convection, but there are no known products that specifically protect against all three methods of thermal heat transfer.

When using a batt of fiberglass or a blanket of fiberglass or similar material on which a; facing is attached, the insulation is not very strong and can have a lower tear strength. Such insulation is usually laid down, on top of a structure. Such insulation is not conducive to hanging under a roof of a building, such as a metal building. Such insulation materials can tear and sag too easily. Additionally, the method of installing the insulation between roof supports instead of over them can create insulation systems that provide uneven and inconsistent thermal insulative protection. Therefore, a need exists for improve insulation, insulation systems, and method of installing such insulation.

SUMMARY

The present subject matter provides relates to building insulations, building insulations systems, and related methods. More particularly, the present subject matter relates to thermal insulations, thermal insulation systems, and methods of installation that provide a continuous thermal barrier for the inside of the building and provide built-in weight reinforcements to facilitate the support of the thermal insulation when hung from a roof structure, such as a roof supports of a building. Methods related to the installation of such insulations and systems disclosed herein are also provided.

In some embodiments, the present subject matter includes an insulation product that can be covered with a tough, reinforced facing with evenly spaced straps that run between the insulation and the reinforced facing. The present subject matter is installed in such a manner as to support the weight of the thermal insulation installed. In some embodiments, a thermal insulation and system is disclosed that also provides a thermal barrier against three different aspects of heat transfer: conduction, convection and radiation.

Thus, it is an object of the presently disclosed subject matter to provide building insulations and building insulations systems as well as methods related thereto. While one or more objects of the presently disclosed subject matter having been stated hereinabove, and which is achieved in whole or in part by the presently disclosed subject matter, other objects will become evident as the description proceeds when taken in connection with the accompanying drawings as best described hereinbelow.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present subject matter including the best mode thereof to one of ordinary skill in the art is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:

FIG. 1A illustrates a perspective view of a portion of an embodiment of a blanket of insulation according to the present subject matter;

FIG. 1B illustrates a perspective view of a portion of an embodiment of a insulation system partially installed comprising blankets of insulation according to FIG. 1A and in accordance with the present subject matter;

FIG. 1C illustrates a perspective view of a portion of an embodiment of a blanket of insulation according to FIG. 1;

FIG. 2A illustrates a perspective view of a portion of another embodiment of a blanket of insulation according to the present subject matter;

FIG. 2B illustrates a perspective view of a portion of an embodiment of a insulation system partially installed comprising blankets of insulation according to FIG. 2A according to the present subject matter;

FIG. 3A illustrates a partial cross-sectional perspective view of a portion of a building with a portion of an embodiment of a insulation system showing a vertical cross-section of a blanket of insulation installed in the building according to the present subject matter; and

FIG. 3B illustrates a schematic cross-sectional view of a portion of a blanket of insulation of an insulation system installed in a building according to the present subject matter.

Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present subject matter.

DETAILED DESCRIPTION

Reference now will be made to the embodiments of the present subject matter, one or more examples of which are set forth below. Each example is provided by way of an explanation of the present subject matter, not as a limitation. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present subject matter without departing from the scope or spirit of the present subject matter. For instance, features illustrated or described as one embodiment can be used on another embodiment to yield still a further embodiment. Thus, it is intended that the present subject matter cover such modifications and variations as come within the scope of the appended claims and their equivalents. It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present subject matter, which broader aspects are embodied in exemplary constructions.

Although the terms first, second, right, left, front, rear, top, bottom, etc. may be used herein to describe various features, elements, components, regions, layers and/or sections, these features, elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one feature, element, component, region, layer or section from another feature, element, component, region, layer or section. Thus, a first feature, element, component, region, layer or section discussed below could be termed a second feature, element, component, region, layer or section without departing from the teachings of the disclosure herein.

Similarly, when a layer or coating is being described in the present disclosure as “on” or “over” another layer or substrate, it is to be understood that the layers can either be directly contacting each other or have another layer or feature between the layers, unless expressly stated to the contrary. Thus, these terms are simply describing the relative position of the layers to each other and do not necessarily mean “on top of” since the relative position above or below depends upon the orientation of the device to the viewer.

Embodiments of the subject matter of the disclosure are described herein with reference to schematic illustrations of embodiments that may be idealized. As such, variations from the shapes and/or positions of features, elements or components within the illustrations as a result of, for example but not limited to, user preferences, manufacturing techniques and/or tolerances are expected. Shapes, sizes and/or positions of features, elements or components illustrated in the figures may also be magnified, minimized, exaggerated, shifted or simplified to facilitate explanation of the subject matter disclosed herein. Thus, the features, elements or components illustrated in the figures are schematic in nature and their shapes and/or positions are not intended to illustrate the precise configuration of the subject matter and are not intended to limit the scope of the subject matter disclosed herein.

It is to be understood that the ranges and limits mentioned herein include all ranges located within the prescribed limits (i.e., subranges). For instance, a range from about 100 to about 200 also includes ranges from 110 to 150, 170 to 190, 153 to 162, and 145.3 to 149.6. Further, a limit of up to about 7 also includes a limit of up to about 5, up to 3, and up to about 4.5, as well as ranges within the limit, such as from about 1 to about 5, and from about 3.2 to about 6.5.

As used herein, the term “polymer” generally includes, but is not limited to, homopolymers; copolymers, such as, for example, block, graft, random and alternating copolymers; and terpolymers; and blends and modifications thereof.

As used herein, the term “blanket of insulation” generally includes, but is not limited to, an insulation body that comprises insulation material that can have a facing secured thereto. The insulative body, for example, can include in some embodiments a batt of insulative material that can have a length and a width.

As disclosed herein, a building insulation is provided that comprises an insulation body that has a bottom surface and a top surface and a length and a width with the length being longer than the width. When the building insulation is installed, the top surface can face inward toward the building or structure. For example, the top surface can face the roof structure and roof supports, while the bottom surface can face outward away from the roof structure and roof supports. The insulation body can be, for example, a batt, or batting, of an insulative material, such as fiberglass, mineral wool or cellulosic insulative material. The insulation body is configured to reduce conduction of heat through the insulation body. The insulation body is often measured by its R-value which measures the capacity of an insulating material to resist heat flow with a higher the R-value indicating greater insulating power.

The building insulation also comprises a facing secured to the bottom surface of the insulation body. The facing can be a vapor retardant that provides a vapor barrier and can provide a more finished appearance on the bottom of the insulation body so that the facing can, in some instances, comprise an interior surface of the building in which the building insulation is installed. The facing can extend beyond a sidewall of the insulation body along the length of the insulation body to create a facing flange. The facing flange can be used to overlap the facing of an adjacent second blanket of insulation to form a sealing seam.

The building insulation can further comprise a plurality of reinforcing straps secured in between the facing and the bottom surface of the insulation body. The reinforcing straps can be spaced apart from one another and can provide reinforcing strength for attachment of the building insulation to a building. The reinforcing straps are configured to receive one or more fasteners that secure the building insulation to a structure, or building, and support the weight of the building, insulation against the one or more fasteners. In some embodiments, the building insulation can also comprise a radiant barrier secured to the top surface of the insulation body so that the radiant barrier to reflect heat. These and other features of the present subject matter are described in more detail below.

Referring to FIGS. 1A and 1C, a building insulation, generally designated 10, is provided that comprises an insulation body 12, reinforced facing 14, and a plurality of reinforcing straps 16. In particular, the building insulation 10 can comprise the insulation body 12 comprising a bottom surface 12A and a top surface 12B. The insulation body 12 comprises a material that reduces conduction of heat through the insulation body. For example, in some embodiments, the insulation body 12 can comprise fiberglass, mineral wool or cellulosic insulative material. In some embodiments, the insulation body 12 can be a batt or batting that can have a lower shear tear strength that would likely limit the ability of the insulative body 12 alone to be hung from roof supports in a building for long-term insulating purposes. The insulation body 12 can have a length L and a width W with the length L being longer than the width W as shown in FIG. 1C. The insulation body 12 can have a height H as shown in FIG. 1C that can be different for different application of the insulation 10 and based different desired or required R-values to be obtained. In some embodiments, the insulation body 12 can be sized to virtually any length required with the width of insulation body 12 being about five feet. In some embodiments, the width of insulation body 12 can be about three feet, about four feet, about six feet, or about seven feet. Regarding the length, the insulation body 12 can have a length L that allows the insulation body 12 to extend along the length of the building.

The facing 14 can be secured to the bottom surface 12A of the insulation body 12. The facing 14 can be applied to the insulation body 12 to serve as a vapor retarder, or vapor barrier, as well as a protected cover over the insulation body 12. The facing 14 can provide a vapor barrier and a clean finished look. For example, the facing 14 can offer a clean finished look in any metal building environment. The facing 14 can comprise a variety of materials. In some embodiments, the facing can be, for example, kraft paper, white vinyl sheeting, or a metallic foil. In some embodiments, the facing 14 can comprise a polypropylene sheet, such as a nonwoven fabric, a scrim fabric, or a film, with a natural kraft paper backing on the back side. In some embodiments, the facing 14 can be a polymer coated scrim. In some embodiments, the facing 14 can comprise a polypropylene insulation facing, with a metallized polyester (foil like) backing on back side that can generally be used in a typical metal building that does not require heavy facing. Such a facing 14 can be different colors, including white or black. In some embodiments, the facing can comprise polypropylene insulation facing with a woven fiberglass/polyester blend fabric backing on a back side of the facing. In some embodiments, the facing 14 can generally be made of reinforced polypropylene or vinyl insulation facing. However, other types of polymers and fabric or film constructions can be used. As stated above, the facing 14 may be made of other sufficiently strong, durable, pliable materials that can be sealed to produce a tight air barrier. The facing 14 can be secured to the bottom surface 12A of the insulation body 12 with a binder. In fact, a binder can be used to secure the reinforcing straps 16 between the facing 14 and the insulation body 12 and secure the facing 14 to the insulation body 12.

As stated, the plurality of reinforcing straps 16 can be secured between the bottom surface 12A of the insulation body and the facing 14. The straps 16 can be flexible, strong and durable material, for example, a durable fabric. The reinforcing straps 16 can be spaced apart from one another and can provide reinforcing strength for attachment of the building insulation 10 to a building B (see FIG. 3A). In some embodiments, the straps 16 can be spaced between about six (6) inches apart and about twenty-four (24) inches apart. In some embodiments, the straps 16 can be spaced approximately twelve (12) inches apart and extend the length of the insulation body 12. In some embodiments, the reinforcing straps 16 can extend in a length direction along at least a portion of the length of the insulation body 12. The number of reinforcing straps 16 and the distance D_S (see FIG. 1B) therebetween can be a factor of the tear strength of the reinforcing straps 16 and/or the distance between the roof supports, such as the distance between purlins that support roof decking and to which the insulation 10 can be attached. For example, if the distance between the purlins is longer, more straps 16 may be in the insulation 10 with a shorter distance D_S between the straps 16. If the distance between the purlins is shorter, then less straps 16 may be present and the distance D_S between the straps 16 may be longer. In some embodiments, the outer two straps 16A, 16B (see FIG. 1A) can be inset about two (2) from the outer side edges of the insulation body 12.

The reinforcing straps 16 can comprise different materials. For example, the reinforcing straps 16 can comprise strips of fabric. In some embodiments, the strips of fabric can comprise at least one of nonwoven material, woven material, braided material, or a knit material. Such strips of fabric are more flexible than an extruded or molded strip, plastic flat rod or plate. For example, the reinforcing straps 16 can comprise strips of a woven polypropylene fabric, also referred to a webbing, in some embodiments. In some embodiments, the straps 16 can comprise a polyester, a polyethylene, a nylon, an aramid, and/or other durable thermoplastic polymer fibers or yarns in a woven, knitted, or braided fabric, or in a fabric formed by a nonwoven process. Additionally, the straps 16 can comprise natural fibers or yarns or a combination of natural and synthetic fibers and/or yarns. In some embodiments, the straps 16 can comprise a flexible laminate substrate. For instance, the straps 16 can be formed from strips of high strength facing material, such as a polymer coated scrim with a high tear strength. The use of such strips of high strength facing material can allow a different type of facing material to be used as facing 14 that provides different properties from the facing material used in the facing material strips used for the straps.

The straps 16 can have a higher tear strength than the facing 14 and are sturdy and durable. The tear strength of the reinforcing straps 16 can also be stronger than the insulation body 12. The material used for the reinforcing strap 16 can be selected based on the weight of the insulation 10 that the reinforcing strap 16 is expected to support when a blanket of the insulation 10 when pulled tight and installed. The forces generated upon the reinforcing strap 16 by the tautness of the blanket of insulation 10 once the fasteners are secured therein can also be taken into consideration. The number of reinforcing straps 16 per unit area of the insulation 10 can also be taken into consideration when selecting the material.

The straps 16 can have a width W_S of between about one (1) inch and about four (4) inches. The straps 16 can have a width W_S of between about one, (1) inch and about three (3) inches. For example, the straps 16 can have a width W_S of about two (2) inches.

Thus, as shown in FIGS. 1A-1C, the insulation body 12 can be attached on one side to the facing 14 using a binder 20. The reinforcing straps 16 can be secured between the insulation body 12 and the facing 14 with the binder as well. The facing 14 can have a width W_F that is wider than the width W of the insulation body 12 as measured along the insulation body 12 as shown in FIG. 1C. Thereby, in some embodiments as shown, the facing 14 can extend beyond a sidewall 12C of the insulation body 12 along the length of the insulation body 12 to create a facing flange 18. In some embodiments, the facing 14 can extend between about one (1) inch and about four (4) inches beyond the width W of the insulation body 12 on one side to create the flange 18. For example, in some embodiments, the facing 14 can extend approximately two (2) inches beyond the width W of the insulation body 12 on one side to create the flange 18. Such a flange 18 extends the length of a blanket of the insulation 10. As stated above, in some embodiments, the reinforcing straps 16 can be inset approximately two (2) inches from the side edges of insulation body 12 and can be spaced approximately twelve (12) inches apart from one another while extending the length L of the insulation 10. In the embodiment shown, the insulation body 12 and the facing 14 can be sized to virtually any length required with the width of insulation body 12 being about five (5) feet and the width of the facing 14 being approximately two (2) inches wider than the insulation body 12.

FIG. 1B illustrates the sealing of seams between eave strut 22 and insulation 10_2A and between adjacent lengths of insulation 10_2A and insulation 10₂₈. There is facing flange 18_2A of insulation 10_2A and seam 34 between eave strut 22 and insulation 10_2A. The facing 14_2A extends beyond a sidewall 12C_2A of the insulation body 12_2A along the length of the insulation body 12_2A to form the facing flange 18_2A for forming a sealed seam along the adjacent structure of an installed insulation 10_2B. The facing flange 18_2A overlaps the bottom of the adjacent piece of thermal insulation 10₂₈ and can be secured to produce a tight air seal below the insulation bodies 12_2A and 12_2B of blankets of insulation 10_2A and 10_2B. For example, the facing flange 18_2A may be secured to the facing 14_2B of the insulation 10_2B by tape, adhesive, or other binder. As shown, tape 23 can be used to secure the facing flange 18_2A to the facing 14_2B of the insulation 10_2B. Furthermore, the seams 34 where insulation 10_2A meets the eave strut 22 can be secured to produce a tight air seal, for example, by tape 23.

Referring to FIGS. 2A and 2B, a similar building insulation blanket, generally designated 50 is provided that also provides protection against radiant heat. As with the embodiments described above, the building insulation 50 can comprise an insulation body 12 comprising a bottom surface 12A and a top surface 12B. The insulation body 12 can be configured to reduce conduction of heat through the insulation body. As above, the insulation body 12 can have a length and a width with the length being longer than the width. The building insulation 50 can comprise a facing 14 secured to the bottom surface 12A of the insulation body 12 that can provide a level of convective thermal protection. The building insulation 50 can further comprise a plurality of reinforcing straps 16 secured between the facing 14 and the bottom surface 12A of the insulation body 12, such that the reinforcing straps 16 are spaced apart from one another and provide reinforcing strength for attachment of the building insulation 50 to a building. Additionally, the building insulation 50 can comprise a radiant barrier 52 secured to the top surface 12B of the insulation body 12 of each blanket of insulation 50. The radiant barrier 52 can provide a level of thermal protection against radiant heat by having an outer surface that can reflect radiant heat. In some embodiments, the radiant barrier can be vapor permeable. In some embodiments, the radiant barrier can be a vapor barrier.

The radiant barrier 52 can comprise a variety of materials as long as it has the ability to reflect radiant heat away from the insulation body 12. In some embodiments, the radiant barrier 52 can comprise at least one of a metal foil or a metallized polyester that covers the top surface 12A of the insulation body 12. Gaps between the radiant barrier 52 and roof structure 40, such as roof decking, under which the building insulation 50 is installed can allow air to circulate above the radiant barrier 52 to remove the reflected heat. The area above the insulation 50 can be vented from the outside allowing a natural convection current that vents the underside of the roof above the insulation 50.

As shown in the embodiment of the building insulation 50 in FIG. 2A, the facing 14 can extend beyond a sidewall 12C of the insulation body 12 along the length of the insulation body 12 to form a facing flange 18. Additionally, in some embodiments as shown, the radiant barrier 52 can extend beyond the sidewall 12C of the insulation body 12 along the length of the insulation body 12 to form a radiant barrier flange 54 for forming a sealed seam along an adjacent structure, such as a eave strut, a purlin, or an adjacent blanket of the insulation 50. In some embodiments, however, a radiant flange 54 may not be present so that a continuous air tight barrier can be formed on the facing side of the insulation 50 by the facing 14, while no such continuous air or vapor barrier is formed on the top surface above the insulation body 12.

Thus, the insulation 50 can be formed by the insulation body 12 being laminated on the underside, or bottom surface, by a durable insulation scrim facing 14 with a facing flange 18 extending beyond the width of the insulation body 12. The top side, or top surface, of the insulation body 12 can be covered or coated with a radiant barrier 52 with a radiant barrier flange 20 extending beyond the width of the insulation body 12 on the same side as facing flange 18.

FIG. 2B illustrates the sealing of seams between eave strut 22 and insulation 50_1A and between adjacent lengths of insulation 50_1A and insulation 50_1B. The insulation 50_1A can comprise a radiant barrier 52_1A secured to a top surface of an insulation body 12_1A and insulation 50_1B can comprise a radiant barrier 52_1B secured to a top surface of an insulation body 12_1B. As described above, insulation 50_1A can comprise a facing 14_1A and reinforcing straps 16_1A secured to a bottom surface of an insulation body 12_1A and insulation 50_1B can comprise a facing 14_1B and reinforcing straps 16_1B secured to a bottom surface of an insulation body 12_1B. There is a radiant barrier flange 54_1A of insulation 50_1A and scrim facing flange 18_1A of insulation 50_1A. Additionally, there is a seam 34 between eave strut 22 and insulation 50_1A. The facing 14_1A extends beyond a sidewall 12C_1A of the insulation body 12_1A along the length of the insulation body 12_1A to form the facing flange 18_1A and the radiant barrier 52_1A extends beyond the sidewall 12C_1A of the insulation body 12_1A along the length of the insulation body 12_1A to form the radiant barrier flange 54_1A for forming a sealed seam along the adjacent structure of an installed insulation 50_1B. The radiant barrier flange 54_1A overlaps the top of the adjacent radiant barrier 52_1B of the insulation 50_1B. In some embodiments, the radiant barrier flange 54_1A is secured to the radiant barrier 52_1B of insulation 50_1B to produce a tight air seal above the blankets of insulation 50_1A, and 50_1B. For example, the radiant barrier flange 54_1A may be secured by tape, adhesive, or other binder. Similarly, the facing flange 18_1A overlaps the facing 14_1B of the adjacent piece of thermal insulation 50_1B and can be secured to produce a tight air seal below the blankets of insulation 50_1A, and 50_1B. For example, the facing flange 18_1A may be secured by tape, adhesive, or other binder. As shown, tape 23 can be used to secure the facing flange 18_1A to the facing 14_1B of the insulation 50_1B. Furthermore, the seams 34 where insulation 10 meet the eave strut 22 can be secured to produce a tight air seal, for example, by tape 23.

Referring to FIGS. 3A and 3B, an insulation system, generally designated 100, employing the building insulation 10 is provided. The building insulation system 100 can comprise a plurality of blankets of building insulation 10. Each blanket of insulation 10 can comprise an insulation body 12 as described above that can have a bottom surface and a top surface with the insulation body 12 configured to reduce conduction of heat through the insulation body 12. Each blanket of insulation 10 can also comprise a facing 14 secured to the bottom surface 12A of the insulation body 12 and a plurality of reinforcing straps 16 secured between the bottom surface of the insulation body 12 and facing 14. As described above, the reinforcing straps 16 can be spaced apart from one another and providing reinforcing strength for attachment of the building insulation 10 to a building. B. The building insulation system 100 can also comprise a plurality of fasteners 26 for securing the plurality of blankets of building insulation 10 to the building B to insulate the building B. The fasteners 26 can be inserted into the facing 14, one or more of the reinforcing straps 16, and the insulation body 12 and then secured to a roof support, such as an eave strut 22 and/or an underside of a purlin 24 using the fastener 26. The reinforcing straps 16 of each blanket of insulation 10 are configured to support the weight of the building insulation 10 against the one or more fasteners 26 as described above. The fasteners 26 can comprise a variety of fastener, such as spikes, screws, spikes and ferrels, screws and ferrels, weld pins or the like depending upon which type of material used to construct the roof supports. When ferrels are used, they can keep the spikes and screws from being inserted too far in the roof support to prevent the compressing of the insulation 10. Additionally, the facing 14 can secured to eave strut 22 through strap 16 using a fastener, such as a self-taping screw and a washer. Similarly, weld pins can be spot welded to the roof support after insertion such that the length of the pin prevents a permanent compression of the insulation.

In some embodiments, air gaps 33 can be maintained above the insulation 10 between the insulation 10 and the roof decking 40 to allow airflow above the insulation 10. This configuration can be advantageous for embodiments of insulation such as insulation 50 described above that comprises a radiant barrier to aid in removing the reflected radiant heat with the flow of air.

The insulation 10 can be pulled tight and anchored to the underside of purlin 24 with a fastener, 26, such a cupped weld pin inserted into strap 16. Flange 18 overlaps the edge of the adjacent piece of insulation 10 and can be taped securely to produce a tight air barrier. This process is repeated for the entire length of insulation 10 and for each blanket of insulation 10.

The building insulation system can further comprise tape 23 (see FIGS. 1B and 2B) for sealing seams between adjacent installed blankets of building insulation. The seam 28 between insulation 10 and wall insulation 36 can be sealed with a tape 23 and the seam 34 between insulation 10 and the main building frame 30 can also be sealed with a tape 23 to prevent air leakage. Thereby, the insulation system 100 can create an air tight barrier to aid in the creation of additional thermal barrier that aids against thermal convection.

In some embodiments, the facing 14 of each blanket of building insulation can extend beyond a sidewall 12C of the insulation body 12 along the length L of the insulation body 12 to create a facing flange 18. The facing flange 18 can be configured to overlap an adjacent facing of a blanket of building insulation upon installation as described above with reference to FIG. 1A.

By securing the insulation system 100 to the underside of the roof supports, the insulation system is continuous such that more consistent levels of R-values across the whole system can be obtained.

In some embodiments (not shown), the reinforcing straps can be configured to support the weight of the building insulation and the weight of additional loose insulation material positioned above the top surface of insulation body against the one or more fasteners. In such embodiments, the insulation body can have sealable slits therethrough through which additional loose insulation material can be transported to a location above the top surface of the insulation body. Once the full length of the blanket of insulation has been installed a small slit can be made in the center of insulation between each purlin to allow the installation of the loose fill insulation. Loose fill insulation can be installed below roof decking through the small slits and can be supported by insulation and the straps. Loose fill insulation can completely fill the cavity above insulation between purlins. Upon completion of the installation of loose fill insulation, small slits can be taped closed.

The insulation products and systems disclosed herein can be installed from the underside of the roof without requiring access from above the roof supports. The insulation product of the present subject matter can be sealed, providing continuous insulation for the interior for the building. Further, the insulation product of the present subject matter provides a means to achieve higher resistance to thermal heat transfer than what is commonly achieved at the present time, meeting current metal building energy codes.

Thus, as described above, a method of installing building insulation within a building is provided that comprises the step of providing a plurality of blankets of building insulation. Each blanket of insulation can comprise an insulation body having a bottom surface and a top surface and a facing secured to the bottom surface of the insulation body. Each blanket of insulation can also comprise a plurality of reinforcing straps secured between the bottom surface of the insulation body and the facing. The reinforcing straps can be spaced apart from one another and can provide reinforcing strength for attachment of the building insulation to a building. The method also comprises providing a plurality of fasteners for securing the plurality of blankets of building insulation to a roof support to insulate the building. A first blanket of insulation from the plurality of blankets of insulation can be placed against a roof support of the building. The first blanket of insulation from the plurality of blankets of insulation can then be secured to the roof support, such as an eave strut or purlin of the building, by inserting the fasteners into one or more of the plurality of the reinforcing straps and securing the fasteners to the roof support.

A second blanket of insulation of the plurality of blankets of insulation can be placed adjacent the first blanket of insulation and against the roof support of the building. The second blanket of insulation from the plurality of blankets of insulation can be secured to the roof support of the building by inserting fasteners into one or more of the plurality of the reinforcing straps and securing the fasteners to the roof support. The facing on each blanket of insulation can extend beyond a sidewall of the insulation body along the length of the insulation body to form a facing flange. The facing flange of the first blanket of insulation can overlap the facing the adjacent second blanket of insulation to form a sealing seam. Tape can be placed over the seam formed between the first blanket of insulation and the second blanket of insulation.

Installation must be performed from a stable platform or aerial lift by trained workmen using the appropriate OSHA (Occupational Safety and Health Administration) required fall restraint system and personal protection equipment.

Some advantages of the presently disclosed subject matter include a packaged insulation that provides thermal protection against conduction, convection and radiation. Further, the installation of the insulation of the present subject matter is simple as compared to the typical installation methods for thermal insulation. Additionally, the insulation of the present subject matter can be adapted to many different roof types and configurations with minor difficulty providing opportunity for improved energy efficiency for all construction types.

These and other modifications and variations to the present subject matter may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present subject matter, which is more particularly set forth herein above. In addition, it should be understood the aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the present subject matter. Reference signs incorporated in the claims solely to ease their understanding, and do not limit the scope of the claims.

Claims

1. A building insulation comprising: an insulation body comprising a bottom surface and a top surface, the insulation body configured to reduce conduction of heat through the insulation body and having a length and a width with the length being longer than the width;a facing secured to the bottom surface of the insulation body; anda plurality of reinforcing straps secured between the facing and the bottom surface of the insulation body, the reinforcing straps being spaced apart from one another and providing reinforcing strength for attachment of the building insulation to a building.

2. (canceled)

3. The building insulation according to claim 1, wherein the facing is vapor barrier and is secured to the bottom surface of the insulation body with a binder.

4. The building insulation according to claim 1, further comprising a radiant barrier secured to the top surface of the insulation body, the radiant barrier configured to reflect radiant heat.

5. The building insulation according to claim 4, wherein the radiant barrier comprises at least one of a metal foil or a metallized polyester that covers the top surface of the insulation body.

6. (canceled)

7. The building insulation according to claim 1, wherein the facing extends beyond a sidewall of the insulation body along the length of the insulation body to create a facing flange.

8. The building insulation according to claim 1, wherein the reinforcing straps are configured to receive one or more fasteners that secures the building insulation to a a roof support of a building, the reinforcing straps being configured to support the weight of the building insulation against the one or more fasteners.

9. The building insulation according to claim 1, wherein the reinforcing straps comprises strips of fabric.

10. (canceled)

11. The building insulation according to claim 1, wherein the reinforcing straps extend in a length direction along at least a portion of the length of the insulation body.

12. (canceled)

13. A building insulation system that forms a substantially continuous insulation on a roof supports of a building, the building insulation system comprising: a plurality of blankets of building insulation, each blanket of insulation comprising: an insulation body comprising a bottom surface and a top surface, the insulation body configured to reduce conduction of heat through the insulation body and having a length and a width with the length being longer than the width;a facing secured to the bottom surface of the insulation body; anda plurality of reinforcing straps secured between the bottom surface of the insulation body and the facing, the reinforcing straps being spaced apart from one another and providing reinforcing strength for attachment of the building insulation to a building; anda plurality of fasteners for securing the plurality of blankets of building insulation to a roof support of the building by inserting the fasteners into one or more of the reinforcing straps so that the plurality of blankets of building insulation are aligned adjacent to one another without a roof support disposed therebetween.

14. (canceled)

15. The building insulation system according to claim 13, wherein the facing is vapor barrier and is secured to the bottom surface of the insulation body of each blanket of insulation with a binder.

16. The building insulation system according to claim 13, further comprising tape for sealing seams between adjacent installed blankets of building insulation.

17. The building insulation system according to claim 16, wherein the facing of each blanket of building insulation extends beyond a sidewall of the insulation body along the length of the insulation body to create a facing flange, the facing flange configured to overlap an adjacent facing of a blanket of building insulation upon installation.

18. The building insulation system according to claim 13, further comprising a radiant barrier secured to the top surface of the insulation body of each blanket of insulation, the radiant barrier configured to reflect radiant heat.

19. (canceled)

20. (canceled)

21. The building insulation system according to claim 13, wherein the reinforcing straps of each blanket of insulation are configured to support the weight of the building insulation against the one or more fasteners.

22. The building insulation system according to claim 13, wherein the reinforcing straps of each blanket of insulation comprises strips of fabric.

23. (canceled)

24. (canceled)

25. The building insulation system according to claim 1, wherein the plurality of fasteners comprise at least one of screws or weld pins.

26. A method of installing building insulation within a building, the method comprising: providing a plurality of blankets of building insulation, each blanket of insulation comprising: an insulation body comprising a bottom surface and a top surface, the insulation body configured to reduce conduction of heat through the insulation body and having a length and a width with the length being longer than the width;a facing secured to the bottom surface of the insulation body; anda plurality of reinforcing straps secured between the bottom surface and the insulation body, the reinforcing straps being spaced apart from one another and providing reinforcing strength for attachment of the building insulation to a building; andproviding a plurality of fasteners for securing the plurality of blankets of building insulation to a roof support of the building;placing a first blanket of insulation from the plurality of blankets of insulation against the roof support of the building;securing the first blanket of insulation from the plurality of blankets of insulation to the roof support of the building by inserting fasteners into one or more of the plurality of the reinforcing straps and securing the fasteners to the roof support.

27. The method according to claim 26, further comprising: placing a second blanket of insulation from the plurality of blankets of insulation adjacent the first blanket of insulation and against the roof support of the building;securing the second blanket of insulation from the plurality of blankets of insulation to the roof support of the building by inserting fasteners into one or more of the plurality of the reinforcing straps and securing the fasteners to the roof support.

28. The method according to claim 27, wherein the facing on each blanket of insulation extends beyond a sidewall of the insulation body along the length of the insulation body to form a facing flange and further comprising overlapping the facing flange of the first blanket of insulation over the facing the adjacent second blanket of insulation to form a sealing seam.

29. The method according to claim 27, further comprising placing tape over the seam formed between the first blanket of insulation and the second blanket of insulation.