Fibrous Insulation Batts Having One Or More Slits And Methods For Installing Them

BACKGROUND OF THE DISCLOSURE
1. Field of the Disclosure

The present disclosure relates generally to fibrous insulation batts and methods for installing them. The present disclosure relates more particularly to fibrous insulation batts having one or more slits that may facilitate compression of one or more portions of the fibrous insulation batt during installation to accommodate one or more rafters attached to a roof deck.

2. Technical Background

Insulation materials such as fiberglass batts, rolls, blankets, or blown-in insulation are typically used to reduce the rate of heat transfer between two areas separated by a boundary. For example, in an attic, insulation material can be applied to the interior surface of the roof deck to slow the transfer of heat through the roof deck, that is, from the exterior of the house to the attic or vice versa. In another application, insulation material is applied to exterior walls (e.g., between wood studs) and covered with wallboards to slow the rate of heat transfer through the exterior wall and the wallboard.

Generally, the rate of heat transfer through (e.g., R-value of) a particular insulation material having a particular density decreases as the thickness of the material is increased. In some instances, a thickness of insulation to be installed against a roof deck to yield a desired heat transfer rate may be greater than the distance the roof support structure (e.g., rafters) extends below the roof deck. Pre-cut insulation batts and blown-in insulation are two options that could be used in such situations, although they are easier to install in situations where the roof support structure extends below the roof at a distance that is greater than the thickness of the insulation.

Insulation batts often have a facing material (e.g., paper) that extends outward from opposing sides of the insulation batt. Installing an insulation batt by securing its facing material to the underlying roof support structure is a straightforward approach when the roof support structure extends below the roof deck at a distance that is greater than the thickness of the insulation. However, this approach is generally undesirable with conventional insulation batts when the desired thickness of insulation is greater than the distance the rafters hang below the roof deck because the insulation batt is compressed such that the facing is in a position to be secured (e.g. stapled) to one or more rafters. Compressing the insulation can create air gaps that increase the rate of heat transfer through the insulation. Another alternative is for the installer to hang the insulation batt with wire hangers that extend below the roof deck. Yet another alternative is to hang netting below the rafters and blow in loose insulation between the roof deck and the netting. These methods are labor-intensive and time consuming.

Accordingly, what is needed is an insulation batt having a thickness greater than a typical rafter depth, but that is also easier to install without having to undesirably compress the insulation batt.

SUMMARY OF THE DISCLOSURE

One aspect of the disclosure is a fibrous insulation batt comprising:

- a body of fibrous insulation having
  - a first face and a second face that are substantially parallel to each other;
  - a third face and a fourth face that are substantially parallel to each other and substantially perpendicular to the first and second faces; and
  - a first slit that extends from the second face toward, but stopping short of, the first face, wherein the first slit is substantially parallel to the third face; and
- a facing comprising a first portion that configured to be extendable over the first face, a second portion configured to be extendable over a portion of the third face, and a third portion configured to be extendable over a portion of the fourth face.

Another aspect of the disclosure is a method of installing a fibrous insulation batt as described herein, the method including

- placing a portion of the second face of the body of fibrous insulation that is between the first slit and the fourth face such that the portion of the second face faces a roof deck;
- compressing, against a first rafter that extending from the roof deck, a portion of the body of fibrous insulation that is between the first slit and the third face.

Additional aspects of the disclosure will be evident from the disclosure herein.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are included to provide a further understanding of the methods and devices of the disclosure, and are incorporated in and constitute a part of this specification. The drawings are not necessarily to scale, and sizes of various elements may be distorted for clarity. The drawings illustrate one or more embodiment(s) of the disclosure, and together with the description serve to explain the principles and operation of the disclosure.

FIG. 1 is a schematic exploded perspective view of a fibrous insulation batt according to an embodiment of the disclosure.

FIG. 2 is a schematic perspective view of a fibrous insulation batt according to another embodiment of the disclosure.

FIG. 3 is a schematic front view of a fibrous insulation batt according to another embodiment of the disclosure.

FIG. 4 is a schematic top view of a fibrous insulation batt according to another embodiment of the disclosure.

FIG. 5 is a block diagram of a method for installing a fibrous insulation batt according to another embodiment of the disclosure.

FIG. 6 is a schematic cross-sectional view depicting installation of a fibrous insulation batt according to another embodiment of the disclosure.

FIG. 7 is a schematic cross-sectional view depicting installation of a fibrous insulation batt according to another embodiment of the disclosure.

FIG. 8 is a schematic cross-sectional view depicting installation of a fibrous insulation batt according to another embodiment of the disclosure.

FIG. 9 is a schematic cross-sectional view depicting installation of a fibrous insulation batt according to another embodiment of the disclosure.

FIG. 10 is a schematic cross-sectional view depicting installation of a fibrous insulation batt according to another embodiment of the disclosure;

FIG. 11 is a schematic view of a method according to one embodiment of the disclosure; and

FIG. 12 is a schematic view of a method according to another embodiment of the disclosure.

DETAILED DESCRIPTION

As noted above, the present inventors have noted disadvantages of existing insulation products and methods for installing them. Accordingly, one aspect of the disclosure is a fibrous insulation batt that includes a body of fibrous insulation (e.g., a single portion of interwoven fibrous material). The body of fibrous insulation includes a first face and a second face that are substantially parallel to each other, a third face and a fourth face that are substantially parallel to each other and substantially perpendicular to the first and second faces. In certain embodiments, the body of fibrous insulation further includes a fifth face and a sixth face that are substantially parallel to each other and substantially perpendicular to the first, second, third, and fourth faces. The body of fibrous insulation according to this aspect of the disclosure also includes a first slit that extends from the second face toward, but stopping short of, the first face. The first slit is substantially parallel to the third face.

An installer can place a portion of the second face of the body of fibrous insulation that is between the first slit and the fourth face such that the portion of the second face faces a roof deck. Advantageously, the installer can compress, against a first rafter extending from the roof deck, a portion of the body of fibrous insulation that is between the first slit and the third face. Advantageously, in certain such embodiments, the portion of the body of fibrous material between the first slit and the fourth face can be disposed between the first rafter and a second rafter extending from the roof deck. By compressing the portion of the body of fibrous insulation that is between the first slit and the third face into the first rafter, a space is formed to accommodate the first rafter as some or all of the remaining body of fibrous insulation material fits between the first and second rafters without needing to be compressed. Thus, substantially uncompressed insulation between the first and second rafters may function as designed, whereas the insulation that is compressed under the first rafter is of little functional importance. Also, the installer can attach the second portion of the facing to the first rafter and attach the third portion of the facing to a second rafter that is attached to the roof deck. As described in further detail herein, in certain embodiments one of the facings can be attached before the body of fibrous insulation is disposed against the roof deck, and the other can be attached afterwards.

When used herein, “substantially parallel” means within 20 degrees of being parallel. In certain such embodiments as otherwise described herein, “substantially parallel” is interpreted to mean within 15 degrees of parallel, within 10 degrees of parallel, or even within 7.5 degrees of parallel. Similarly, when used herein, “substantially perpendicular” means within 20 degrees of being perpendicular. In certain such embodiments as otherwise described herein, “substantially perpendicular” is interpreted to mean within 15 degrees of perpendicular, within 10 degrees of perpendicular, or even within 7.5 degrees of perpendicular.

It should be noted that faces of an insulation batt will generally not take the form of perfect planes, but the insulation batt can still have a nominal width, a nominal height, and/or a nominal thickness that correspond respectively to its dimensions. This convention is useful because the somewhat irregular or fluffy faces of the insulation batt can generally be approximated as planar surfaces. For example, a face of an insulation batt might have an average displacement from an opposing face of the insulation batt that corresponds to its nominal thickness in that dimension.

The person of ordinary skill in the art will appreciate that the body of fibrous insulation can be made from a variety of fibrous insulation materials. For example, in certain embodiments as otherwise described herein, the body of fibrous insulation includes one or more of fiberglass material, mineral wool, stone wool, cotton, animal wool, hemp wool, or cellulose. In certain embodiments as otherwise described herein, the fibrous insulation batt is composed of a single portion of interwoven fibrous material. The person of ordinary skill in the art will provide a body of fibrous insulation that provides a desired degree of insulation. In certain embodiments as otherwise described herein, the fibrous insulation batt has an R-value of at least 10, for example, at least 11.

The person of ordinary skill in the art will appreciate that, for insulation of many standard building elements, it can be desirable for the cross-section of the insulation batt to be substantially rectangular. Thus, in certain particular embodiments as otherwise described herein, the first face of the body of fibrous insulation forms an angle of less than 15 degrees, less than 10 degrees, less than 5 degrees, or less than 2.5 degrees with respect to a plane that is parallel with the second face of the body of fibrous insulation.

In certain embodiments as otherwise described herein, the first face and/or the second face of the body of fibrous insulation is within 15 degrees, is within 10 degrees, is within 5 degrees, or is within 2.5 degrees of being perpendicular with a plane that is parallel with the third face and/or the fourth face.

In certain embodiments as otherwise described herein, the first face, the second face, the third face, and/or the fourth face of the body of fibrous insulation is within 15 degrees, is within 10 degrees, is within 5 degrees, or is within 2.5 degrees of being perpendicular with a plane that is parallel with the fifth face and/or the sixth face.

The person of ordinary skill in the art will appreciate that the fibrous insulation batt can be made in a variety of thicknesses, depending on the desired R-value and the particular building element to be insulated. In certain particular embodiments as otherwise described herein, the first face and the second face of the body of fibrous insulation are separated by at least 3.5 inches and/or no more than 14 inches, about 5.5 inches, at least 24 inches and/or no more than 25 inches, about 24.5 inches, at least 15 inches and/or no more than 17 inches, about 16 inches, and/or at least 11 inches and/or no more than 13 inches.

As described above, the fibrous insulation batt also includes a facing. As the person of ordinary skill in the art will appreciate, the facing can be configured to cover the body of fibrous insulation when installed. Accordingly, the facing can include a first portion that is configured to be extendable along the first face, a second portion configured to be extendable over a portion of the third face, and a third portion configured to be extendable over a portion of the fourth face. For example, the first portion of the facing can be attached to the second face of the body of fibrous insulation, with the second section being configured to be foldable up along the third face of the body of fibrous insulation and/or the fourth section being configured to be foldable up along the fourth face of the body of fibrous insulation.

The present inventors have noted that the facing can provide a variety of functions to the fibrous insulation batts described herein. For example, in certain embodiments as otherwise described herein, the facing resists or prevents penetration of vapor. In certain desirable embodiments as otherwise described herein, the facing is rated fire class A.

Similarly, the person of ordinary skill in the art will appreciate from the present disclosure that the facing can be made from a variety of materials. For example, the facing can be formed from paper, such as kraft paper. In certain embodiments, the facing includes a vapor-retarding membrane. A wide variety of vapor-retarding membranes are available to the person of ordinary skill in the art. For example, in certain embodiments as otherwise described herein, the vapor-retarding membrane has a water vapor permeance of no more than about 1 Perm at 25% relative humidity, as tested by ASTM E96 at 23° C. In certain embodiments as otherwise described herein, the vapor-retarding membrane has a water vapor permeance of at least about 5 Perms (e.g., at least about 8 Perms, or at least about 12 Perms, or at least about 15 Perms, or at least about 20 Perms) at 95% relative humidity as tested by ASTM E96 at 23° C. In certain such embodiments, the vapor retarding membrane has not only a water vapor permeance of no more than about 1 Perm at 25% relative humidity, but also a water vapor permeance of at least about 5 Perms (e.g., at least about 8 Perms, or at least about 12 Perms, or at least about 15 Perms, or at least about 20 Perms) at 95% relative humidity as tested by ASTM E96 at 23° C., all as tested by ASTM E96 at 23° C. Thus, the vapor retarding membrane can be a so-called “smart vapor retarder,” i.e., being configured to retard diffusion of water vapor under dry conditions but allow diffusion of water vapor under especially humid conditions. In certain such embodiments, the vapor retarding membrane also has one or more of a) a water vapor permeance of no more than 5 perms, e.g., no more than 2.5 perms or less at 45% average RH, and b) a water vapor perm rating of in the range of 4-15 perms, e.g., in the range of 6-12 perms at 75% average RH as tested by ASTM E96 at 23° C. One suitable such membrane is the MemBrain™ Continuous Air Barrier & Smart Vapor Retarder membrane available from CertainTeed Corporation. The person of ordinary skill in the art can also use materials available under the tradename SMARTBATT from CertainTeed Corporation. Other suitable membranes are disclosed in U.S. Patent Application Publication no. 2016/0185994 and U.S. Pat. No. 6,808,772, each of which is hereby incorporated by reference in its entirety for all purposes, and especially for their description of suitable membranes. The vapor-retarding membrane can be formed from a variety of materials. For example, in certain embodiments as otherwise described herein, the vapor-retarding membrane is a polymer sheet, such as a polymer laminate. Suitable polymers include, for example, polyethylene, polypropylene, nylon (e.g., nylon-6) and poly(vinyl chloride). In other embodiments as otherwise described herein, the vapor-retarding membrane is a sheet, such as a non-woven fabric or kraft paper, having a vapor-retarding coating or laminate formed thereon. The person of ordinary skill in the art will appreciate that many conventional vapor retarding membranes used conventionally in building systems can be used in various embodiments described herein.

As described in more detail below, the second and third portions of the facing can be used to attach the fibrous insulation batt to a building structure. Accordingly, in certain embodiments as otherwise described herein, the second portion of the facing includes a first section having a pull strength of at least 1 pound per linear foot (lbs/ft), for example, at least 2 lbs/ft. The first section of the second portion of the facing can desirably be positioned such that it can be fastened to a building element, e.g., using a fastener such as a staple, a tack or a brad. The person of ordinary skill in the art will understand that the material of the facing can itself provide the desired pull strengths and/or the facing can be reinforced in the first section of the second portion. In certain embodiments, the first section of the second portion of the facing is at an edge of the second portion distal from the first portion.

The second portion of the facing can in certain embodiments also include a second section disposed between the first section and the first portion of the facing. In certain embodiments, the second section need not have a high pull strength; however, the person of ordinary skill in the art will appreciate that the first section and the second section can be formed from the same material, and thus the second section can likewise have a desirably high pull strength. Indeed, the second section and the first section can in some embodiments be indistinguishable sections of a uniform sheet of facing material.

The second portion of the facing is desirably long enough to wrap along the third face of the and be attached to a rafter. Notably, as described in more detail below, the body of fibrous insulation can have a thickness such that it protrudes substantially beyond the rafters between which it is disposed; the second portion of the facing is desirably long enough to accommodate such thickness. Accordingly, the second portion of the facing can, in certain embodiments as otherwise described herein, have a length in the range of 3 inches to 12 inches, for example, 3 inches to 8 inches, or 3 inches to 6 inches (i.e., in a direction extending away from the second section of the second portion of the facing). The first section of the second portion of the facing can in certain embodiments as otherwise described herein have, for example, have a length that is, for example, at least ½ inch or at least 1 inch, e.g., in the range of ½ inch to 6 inches, or 1 inch to 6 inches, or ½ inch to 3 inches, or 1 inch to 3 inches. In certain embodiments as otherwise described herein, the second section of the second portion of the facing has a length that is greater than 2.5 inches and/or less than 3.5 inches extending away from the first portion of the facing, or about equal to 3 inches extending away from the first portion of the facing.

In certain embodiments as otherwise described herein, the first section of the second portion of the facing may be configured to be folded over against the second section of the second portion of the facing. As described in more detail below, this can allow for flexibility in installation. The first section can be defined by a crease provided in the second portion of the facing.

Similarly, in certain embodiments as otherwise described herein, the third portion of the facing includes a first section having a pull strength of at least 1 pound per linear foot (lbs/ft), for example, at least 2 lbs/ft. The first section of the third portion of the facing can desirably be positioned such that it can be fastened to a building element, e.g., using a fastener such as a staple, a tack or a brad. The person of ordinary skill in the art will understand that the material of the facing can itself provide the desired pull strengths and/or the facing can be reinforced in the first section of the third portion. In certain embodiments, the first section of the third portion of the facing is at an edge of the third portion distal from the first portion.

The third portion of the facing can in certain embodiments also include a second section disposed between the first section and the first portion of the facing. In certain embodiments, the second section need not have a high pull strength; however, the person of ordinary skill in the art will appreciate that the first section and the second section can be formed from the same material, and thus the second section can likewise have a desirably high pull strength. Indeed, the second section and the first section can in some embodiments be indistinguishable sections of a uniform sheet of facing material.

The third portion of the facing is desirably long enough to wrap along the third face of the and be attached to a rafter. Notably, as described in more detail below, the body of fibrous insulation can have a thickness such that it protrudes substantially beyond the rafters between which it is disposed; the third portion of the facing is desirably long enough to accommodate such thickness. Accordingly, the third portion of the facing can, in certain embodiments as otherwise described herein, have a length in the range of 3 inches to 12 inches, for example, 3 inches to 8 inches, or 3 inches to 6 inches, or 4 inches to 5.5 inches (i.e., in a direction extending away from the second section of the third portion of the facing). The first section of the third portion of the facing can in certain embodiments as otherwise described herein have, for example, have a length that is, for example, at least % inch or at least 1 inch, e.g., in the range of % inch to 6 inches, or 1 inch to 6 inches, or %2 inch to 3 inches, or 1 inch to 3 inches. In certain embodiments as otherwise described herein, the second section of the third portion of the facing has a length that is greater than 2.5 inches and/or less than 3.5 inches extending away from the first portion of the facing, or about equal to 3 inches extending away from the first portion of the facing.

In certain embodiments as otherwise described herein, the first section of the third portion of the facing may be configured to be folded over against the second section of the third portion of the facing. As described in more detail below, this can allow for flexibility in installation. The first section can be defined by a crease provided in the third portion of the facing.

As described above, the first portion of the facing is configured to be extendable over the first face of the body of fibrous insulation. The first face of the fibrous insulation can be, for example, about the same as the rafter spacing of the roof to be insulated. Accordingly, in certain embodiments as otherwise described herein, the first portion of the facing can have length (i.e., extending between the second portion and a third portion) in the range of 8 inches to 40 inches, e.g., in the range of 8 inches to 28 inches, or in the range of 8 inches to 22 inches, or in the range of 8 inches to 18 inches, or in the range of 8 inches to 16 inches, or in the range of 12 inches to 40 inches, or in the range of 12 inches to 28 inches, or in the range of 12 inches to 22 inches, or in the range of 12 inches to 18 inches, or in the range of 16 inches to 40 inches, or in the range of 16 inches to 28 inches. For example, in certain particular embodiments, the first portion of the facing has a length of about 12 inches, or about 16 inches, or about 24 inches.

In certain embodiments, the facing further includes a first tab that extends from a line where the first portion and the second portion meet, and/or a second tab that extends from a line where the first portion and the third portion meet. In certain such embodiments, an adhesive material may be disposed on (i) the first tab of the facing such that the adhesive material faces away from the first portion of the facing and/or (ii) the second tab of the facing such that the adhesive material faces away from the first portion of the facing. As described in more detail below, tabs of adjacent fibrous insulation batts can be adhered or otherwise attached to one another to provide a better vapor retarding barrier between adjacent batts.

As such, in one embodiment the adhesive material may be disposed on the first tab of the facing and be covered by a backing. In such an embodiment, the fibrous insulation batt may further include an indication on the second tab of the facing of where an adhesive material that is disposed on a facing of another insulation batt is to be adhered. Each tab can be formed, for example, by a folded and glued-together section of the facing material, as would be understood by the person of ordinary skill in the art.

In an alternative embodiment, the adhesive material may be disposed on the second tab portion of the facing and be covered by a backing. In such an embodiment, the fibrous insulation batt may further include an indication on the first tab of the facing of where an adhesive material that is disposed on a facing of another insulation batt is to be adhered.

As described in more detail herein, the first slit can be positioned such that it defines a portion of the body of fibrous insulation that fits between two rafters (or between two building elements more generally) and a portion of the body of fibrous insulation that is compressed against one of the rafters (or against one of the building elements). In certain embodiments as otherwise described herein, the first slit is offset from the third face by a distance in the range of 1 inch to 4 inches, for example, in the range of 1 inch to 3 inches, or in the range of 1 inch to 2 inches, or about 1.5 inches.

The slit is desirably deep enough to allow the part of the body of fibrous material between the first slit and the fourth surface to substantially contact the roof deck at its second face. Accordingly, in certain desirable embodiments as otherwise described herein, the first slit extends from the second face toward the first face by a distance that it is at least about the distance a rafter (or other building element) against which the fibrous insulation is compressed extends from the roof deck. For example, in certain embodiments as otherwise described herein, the first slit extends from the second face toward the first face for a distance in the range of 3 inches to 8 inches, for example, in the range of 3 inches to 6 inches or 3 inches to 4 inches, or about 3.5 inches.

In certain embodiments, the body of fibrous insulation further includes a second slit that extends from the second face toward, but stopping short of, the first face. Such a second slit may be substantially parallel to the fourth face. The use of a second slit can allow an installer to install a fibrous insulation batt as described herein without worrying about directionality; the second slit can be used instead of the first slit when the batt is installed in the reverse direction. Accordingly, in certain embodiments as otherwise described herein, the second slit is offset from the fourth face by a distance in the range of 1 inch to 4 inches, for example, in the range of 1 inch to 3 inches, or in the range of 1 inch to 2 inches, or about 1.5 inches. And in certain embodiments as otherwise described herein, the second slit extends from the second face toward the first face for a distance in the range of 3 inches to 8 inches, for example, in the range of 3 inches to 6 inches or 3 inches to 4 inches, or about 3.5 inches. In certain such embodiments, the first slit and the second slit are symmetrically configured (i.e., with respect to the third and fourth faces).

In certain embodiments of the fibrous insulation batts as otherwise described herein (e.g., when the body of fibrous insulation includes two symmetrically-disposed slits), the second portion and third portion of the facing are symmetrically formed and disposed.

Another aspect of the disclosure includes a method of installing any of the fibrous insulation batts described herein. The method includes placing a portion of the second face of the body of fibrous insulation that is between the first slit and the fourth face such that the portion of the second face faces a roof deck (e.g., disposed between a first rafter and a second rafter extending from the roof deck). The method also includes compressing, against a first rafter that extends from the roof deck, a portion of the body of fibrous insulation that is between the first slit and the third face. In certain desirable embodiments, the method also includes attaching the second portion of the facing to the first rafter and attaching the third portion of the facing to a second rafter that is attached to the roof deck.

In certain embodiments as otherwise described herein, attaching the second portion of the facing involves attaching the second portion of the facing to a surface of the first rafter that faces away from the second rafter. In certain such embodiments, attaching the third portion of the facing may involve attaching the third portion of the facing to a surface of the second rafter that faces the fourth face of the body of fibrous insulation.

Alternatively, in other embodiments as otherwise described herein, attaching the second portion of the facing involves attaching the second portion of the facing to a surface of the first rafter that faces away from the roof deck. In certain such embodiments, attaching the third portion of the facing may involve attaching the third portion of the facing to a surface of the second rafter that faces away from the roof deck.

In certain embodiments, the body of fibrous insulation includes a second slit that extends from the second face toward, but stopping short of, the first face. The second slit may be substantially parallel to the fourth face of the body of fibrous insulation. In certain such embodiments, the method may further include compressing, against the second rafter, a portion of the body of fibrous insulation that is between the second slit and the fourth face. However, in other such embodiments, the portion of the body of fibrous insulation that is between the second slit and the fourth face is not substantially compressed; the second slit can, as described above, allow for the insulation batt to be installed in either direction without reference to which side a slit is on.

As the person of ordinary skill in the art will appreciate, a variety of methods can be used to attach the facing to the rafters. For example, in certain embodiments as otherwise described herein, a hammer tacker is used to attach the facing to the first rafter and/or to the second rafter. But other types of attachment can be used, e.g., staples or nails. As described above, the attachment can be made through the first section of the second portion and/or the first section of the third portion of the facing.

In embodiments in which the second portion of the facing includes a first section configured to be folded over a second section of the second portion of the facing, attaching the second portion of the facing may include, for example, attaching the first section of the second portion of the facing to the first rafter.

In embodiments in which the third portion of the facing includes a first section configured to be folded over a second section of the third portion of the facing, attaching the third portion of the facing may include, for example, attaching the first section of the third portion of the facing to the second rafter.

In embodiments in which the facing includes a first tab that extends from a line where the first portion of the facing and the second portion of the facing meet, the method may further include adhering or otherwise attaching the first tab of the facing to a facing of (e.g., to a tab of a facing of, such as a second tab of a facing of) an adjacent fibrous insulation batt that is attached to the roof deck. Similarly, in embodiments in which the facing includes a second tab that extends from a line where the first portion of the facing and the third portion of the facing meet, the method may further include adhering or otherwise attaching the second tab of the facing to a facing of (e.g., to a tab of a facing of, such as a first tab of a facing of) an adjacent fibrous insulation batt that is attached to the roof deck. Tabs of adjacent fibrous insulation batts can be attached to one another in a variety of ways, e.g., using staples, tape, or an adhesive.

For example, in embodiments in which the first tab has an adhesive disposed thereon, certain methods described herein may include, prior to adhering the first tab of the facing to the facing of the other fibrous insulation batt that is attached to the roof deck, removing a backing from adhesive material that is attached to the first tab of the facing, then adhering the adhesive material to the facing of the adjacent fibrous insulation batt that is attached to the roof deck. In other embodiments, a facing of (e.g., a tab of a facing of, such as a second tab of a facing of) an adjacent fibrous insulation batt has an adhesive disposed thereon, and the method includes removing a backing layer from the adhesive of the facing of the adjacent fibrous insulation batt, then adhering the adhesive material to the first tab of the facing of the fibrous insulation batt.

Similarly, in embodiments in which the second tab has an adhesive disposed thereon, certain methods described herein may, for example, include, prior to adhering the second tab of the facing to the facing of the other fibrous insulation batt that is attached to the roof deck, removing a backing from adhesive material that is attached to the second tab of the facing, then adhering the adhesive material to the facing of the adjacent fibrous insulation batt that is attached to the roof deck. In other embodiments, a facing of (e.g., a tab of a facing of, such as a first tab of a facing of) an adjacent fibrous insulation batt has an adhesive disposed thereon, and the method includes removing a backing layer from the adhesive of the facing of the adjacent fibrous insulation batt, then adhering the adhesive material to the second tab of the facing of the fibrous insulation batt.

The person of ordinary skill in the art will position the body of fibrous insulation in a desired position with respect to a roof deck. For example, in certain embodiments as otherwise described herein, placing the portion of the second face includes placing the portion of the second face such that it substantially contacts the roof deck. Of course, the person of ordinary skill in the art will appreciate that in other embodiments, there is a small amount of space (e.g., no more than about 1 inch) between the portion of the second face of the body of fibrous insulation and the roof deck.

Referring now to the Figures, FIG. 1 is a schematic exploded perspective view of a fibrous insulation batt 100 that includes a body of fibrous insulation 102 (e.g., a single portion of interwoven fibrous material). The body of fibrous insulation 102 includes a first face 104 and a second face 106 that are substantially parallel to each other. The body of fibrous insulation 102 further includes a third face 108 and a fourth face 110 that are substantially parallel to each other and substantially perpendicular to the first face 104 and the second face 106. In the embodiment of FIG. 1, the body of fibrous insulation 102 further includes a fifth face 112 and a sixth face 114 that are substantially parallel to each other and substantially perpendicular to the first face 104, the second face 106, the third face 108, and the fourth face 110. The body of fibrous insulation 102 also includes a first slit 116 (e.g., a cut or separation) that extends from the second face 106 toward, but stopping short of, the first face 104. The first slit 116 is substantially parallel to the third face 108. The slit is configured to allow the portion of the body of fibrous insulation disposed between the slit and the third face to be compressible separate from the body of fibrous insulation on the side of the slit distal to the third face. The fibrous insulation batt 100 also includes a facing 118 (e.g., kraft paper or a vapor retarder membrane) that includes a first portion 120 that is attached (e.g., adhesively) to the first face 104 (see FIG. 2). The facing 118 also includes a second portion 122 that is configured to extend over a portion of the third face 108 (e.g., via folding), and a third portion 124 that is configured to extend over a portion of the fourth face 110 (e.g., via folding).

The body of fibrous insulation 102 may, for example, include one or more of fiberglass material, mineral wool, stone wool, cotton, animal wool, hemp wool, or cellulose. The fibrous insulation batt 100 may have an R-value of at least 11 or of at least 10.

In certain embodiments as otherwise described herein, the first face of the body of fibrous insulation (e.g., a face positioned similarly to the face 104) forms an angle of less than 15 degrees, less than 10 degrees, less than 5 degrees, or less than 2.5 degrees with respect to a plane that is parallel with the second face of the body of fibrous insulation (e.g., a face positioned similarly to the face 106).

In certain embodiments as otherwise described herein, the first face and/or the second face of the body of fibrous insulation is within 15 degrees, within 10 degrees, within 5 degrees, or within 2.5 degrees of being perpendicular with a plane that is parallel with the third face (e.g., a face positioned similarly to the face 108) and/or the fourth face (e.g., a face positioned similarly to the face 110).

In certain embodiments as otherwise described herein, the first face, the second face, the third face, and/or the fourth face of the body of fibrous insulation is within 15 degrees, within 10 degrees, within 5 degrees, or within 2.5 degrees of being perpendicular with a plane that is parallel with the fifth face (e.g., a face positioned similarly to the face 112) and/or the sixth face (e.g., a face positioned similarly to the face 114).

The first face 104 and the second face 106 may, in certain embodiments as otherwise described herein, be separated by at least 3.5 inches and/or no more than 14 inches, about 5.5 inches, at least 24 inches and/or no more than 25 inches, about 24.5 inches, at least 15 inches and/or no more than 17 inches, about 16 inches, and/or at least 11 inches and/or no more than 13 inches. The thickness of the body of fibrous insulation 102 between the first face 104 and the second face 106 may be determined by a minimum desired R-value and/or installation concerns.

In certain embodiments as otherwise described herein, and as described above, the facing 118 includes a material that resists or prevents penetration of vapor on one or both sides of the facing 118. The facing 118 might also include one or more materials that are rated fire class A.

In the embodiment of FIG. 1, the second portion 122 of the facing 118 includes a first section 126 (e.g., a staple resistant section) having a pull strength of at least 1 pound per linear foot (lbs/ft) or at least 2 lbs/ft (e.g., to support the fibrous insulation batt 100 when the section 126 is attached to a roof support structure). The second portion 122 also includes a second section 128 between the first section 126 and the first portion 120 of the facing 118. The first section 126 may have a variety of lengths as described above, e.g., a length that is about equal to 1 inch extending away from the section 128. Additionally, in the embodiment of FIG. 1, the first section 126 is configured to be folded over or under the section 128 (e.g., along the line denoted by reference numeral 137). The second section 128 may have a variety of lengths as described above, e.g., a length that is greater than 2.5 inches and/or less than 3.5 inches extending away from the first portion 120, or about equal to 3 inches extending away from the portion 120. As such, the overall length of the second portion 122 extending away from the first portion 120 can have a variety of lengths as described above, e.g., ranging from 3.5 to 4.5 inches, but other examples are possible.

The third portion 124 of the facing 118 includes a first section 130 (e.g., a staple resistant section) having a pull strength of at least 1 lbs/ft or at least 2 lbs/ft (e.g., to support the fibrous insulation batt 100 when the first section 130 is attached to a roof support structure). The third portion 124 also includes a second section 132 between the first section 130 and the first portion 120 of the facing 118. The first section 130 may have a variety of lengths as described above, e.g., a length that is about equal to 1 inch extending away from the section 132. Additionally, in the embodiment of FIG. 1, the first section 130 is configured to be folded over or under the section 132 (e.g., along the line denoted by reference numeral 139). The second section 132 may have a variety of lengths as described above, e.g., a length that is greater than 2.5 inches and/or less than 3.5 inches extending away from the first portion 120, or about equal to 3 inches extending away from the first portion 120. As such, the overall length of the second portion 132 extending away from the first portion 130 can have a variety of lengths as described above, e.g., ranging from 3.5 to 4.5 inches, but other examples are possible.

Overall, as described above, the facing can have a variety of lengths. For example, in certain embodiments as otherwise described herein, the facing 118 might have a length of about 32.5 inches, about 37.5 inches, or about 24.5 inches along an axis that is parallel with an edge 602 between the face 112 and the face 106. As described above, the first and second portions can have a variety of lengths. For example, the first portion 122 and/or the second portion 124 may have a length between about 4 inches and about 5.5 inches along an axis that is parallel with the edge 602.

As described above, the first slit 116 can be offset from the third face 108 of the body of fibrous insulation by a variety of distances, which can be selected by the person of ordinary skill in the art, for example, based on the thickness of the rafters with which the insulation is to be used. The first slit 116 may, for example, be offset from the third face 108 by at least 1 inch and/or no more than 2 inches, or about 1.5 inches, but other examples are possible. As described above, the depth of the first slit 116 can vary, with the depth being selected by the person of ordinary skill in the art, for example, based on the height of the rafters with which the insulation is to be used. For example, the first slit 116 may extend from the second face 106 toward the first face 104 for at least 3 inches but no more than 4 inches, or about 3.5 inches, but other examples are possible.

In the particular embodiment of FIG. 1, the body of fibrous insulation 102 also includes a second slit 146 that extends from the second face 106 toward, but stopping short of, the first face 104. The second slit 146 is substantially parallel to the fourth face 110. The second slit can be offset from the fourth face by a variety of distances and can have a variety of depths as described above with respect to the first slit. For example, second slit 146 may be offset from the fourth face 110 by at least 1 inch and no more than 2 inches, or about 1.5 inches, but other examples are possible. Similarly, the slit 146 may, for example, extend from the second face 106 toward the first face 104 for at least 3 inches but no more than 4 inches, or about 3.5 inches, but other examples are possible. In certain desirable embodiments, as described above, the first slit and the second slit are formed symmetrically.

In the embodiment of FIG. 1, the facing 118 further includes a first tab 134 that extends (e.g., below the facing 118) from a line 136 where the first portion 120 and the second portion 122 meet. The facing 118 of FIG. 1 further includes a second tab 138 that extends (e.g., below the facing 118) from a line 140 where the first portion 120 and the third portion 124 meet. The first tab 134 and the second tab 138 extend along the entire length of the facing 118 in a direction that is parallel with the third face 108 and/or the fourth face 110. While the embodiment of FIG. 1 has two tabs, the person of ordinary skill in the art will appreciate that in other embodiments, only the first tab or the second tab is present. The use of one or tabs as described herein to physically connect adjacent batts to one another can help prevent sagging, and thus improve the continuity of the insulation by preventing areas where there is a thinner effective layer of insulation. But the person of ordinary skill in the art will appreciate that in other embodiments as otherwise described herein, no tabs are present. In such cases, the person of ordinary skill in the art can determine the degree of sag and use more insulative bodies of fibrous insulation to provide the overall insulated roof with a desired degree of insulation.

In certain embodiments, as described above, an adhesive material may be disposed on the first tab 134 such that the adhesive material faces away from the first portion 120 (indicated by the location 142). Similarly, an adhesive material may also or alternatively be disposed on the second tab 138 such that the adhesive material faces away from the portion 120 (indicated by the location 144).

As such, adhesive material may be attached to the first tab 134 at the location 142 and be covered by a backing (e.g., paper). In this context, the fibrous insulation batt 100 may further include an indication on its facing (e.g., on second tab 138) of where an adhesive material that is disposed on a facing of another insulation batt is to be adhered (indicated by the location 144). Such an indication may include printed text, a differently colored or textured region, or the like.

Additionally or alternatively, adhesive material may be attached to the second tab 138 and be covered by a backing. In this context, the fibrous insulation batt 100 may further include an indication on its facing (e.g., on first tab) 134 of where an adhesive material that is attached to a facing of another insulation batt is to be attached (indicated by the location 142). Such an indication may include printed text, a differently colored or textured region, or the like.

FIG. 2 is a schematic perspective view of the fibrous insulation batt 100. FIG. 2 shows the fibrous insulation batt 100 in an assembled state where the facing 118 is attached to the body of fibrous insulation 102. In this embodiment, the facing 118 is attached in the first portion thereof. However, the person of ordinary skill in the art will appreciate that other configurations are possible.

FIG. 3 is a schematic front view of the fibrous insulation batt 100.

FIG. 4 is a schematic top view of the fibrous insulation batt 100.

FIG. 5 is a block diagram of a method 500 for installing any of the fibrous insulation batts described herein (e.g., the fibrous insulation batt 100 of FIG. 1).

At block 502, the method 500 includes placing a portion of the second face of the body of fibrous insulation that is between the first slit and the fourth face such that the portion of the second face faces a roof deck.

Referring to FIG. 6 and FIG. 7 as alternative examples, an installer may place a portion 400 of the face 106 of the body of fibrous insulation 102 such that the portion 400 faces a roof deck 300. As shown, the portion 400 is between the slit 116 and the face 110, and more specifically, between the slit 116 and the slit 146. The roof deck 300 may be formed of wood or metal, but other examples are possible. FIG. 6 depicts an example where the body of fibrous insulation 102 is aligned such that the face 108 is aligned with a left side of the rafter 302 and the face 110 is aligned with a left side of the rafter 304. FIG. 7 depicts an alternative example where the body of fibrous insulation 102 is aligned such that the face 108 is approximately aligned with a center line of the rafter 302 and the face 110 is approximately aligned with a center line of the rafter 304.

At block 504, the method 500 includes compressing, against a first rafter that is attached to the roof deck, a portion of the body of fibrous insulation that is between the first slit and the third face. For example, the body of fibrous insulation may be compressed such that at least a portion of the second face contacts the roof deck.

Referring to FIG. 8 and FIG. 9 as alternative examples, an installer may compress a portion 402 of the body of fibrous insulation 102 that is between the slit 116 and the face 108 (shown in FIG. 6 and FIG. 7). More specifically, the installer may compress the portion 402 against a rafter 302. As shown in FIG. 9, the method may further include compressing, against a rafter 304, a portion 404 of the body of fibrous insulation 102 that is between the slit 146 and the face 110 (shown in FIG. 6 and FIG. 7).

At block 506, the method 500 includes attaching the second portion of the facing to the first rafter.

At block 508, the method 500 includes attaching the third portion of the facing to a second rafter that is attached to the roof deck.

As shown in FIG. 8, an installer attaches the portion 122 of the facing 118 to a surface 306 of the rafter 302 that faces away from the rafter 304, and attaches the portion 124 of the facing 118 to a surface 308 of the rafter 304 that faces the face 110. More specifically, the installer may use a hammer tacker or another tool to staple through the section 126 and/or the section 128 into the rafter 302, and staple through the section 130 into the rafter 304. In FIG. 8, the distance between the face 110 and the surface 308 is exaggerated so that the portion 124 of the facing 118 is shown with clarity. In practice, the surface 308 may be aligned snugly with the face 110.

In alternative example shown in FIG. 9, an installer attaches the portion 122 of the facing 118 to a surface 310 of the rafter 302 that faces away from the roof deck 300. Additionally, the installer attaches the portion 124 of the facing 118 to a surface 312 of the rafter 304 that faces away from the roof deck 300. More specifically, the installer may use a hammer tacker or another tool to staple through the section 126 and/or the section 128 into the rafter 302, and staple through the section 130 and/or the section 132 into the rafter 304.

In an additional example shown in FIG. 10, an installer adheres the portion 134 of the facing 118 to a facing 146 of a fibrous insulation batt 700 that is attached to the roof deck 300. In doing so, the installer may first remove a backing layer (e.g., paper) from adhesive material that is attached or applied to the surface 142 of the portion 134. Additionally, the installer may adhere the adhesive material on the surface 142 to the facing 146 of the fibrous insulation batt 700. This creates a somewhat airtight cavity between two insulation batts and the roof deck 300. Similarly, the installer may adhere a portion 148 (e.g., covered with adhesive material) of a facing of a fibrous insulation batt 800 that is attached to the roof deck 300 to the portion 138 of the facing 118. In doing so, the installer may first remove a backing layer (e.g., paper) from adhesive material that is attached or applied to the portion 148 and apply the portion 148 to a surface 144.

In FIG. 10, the distance between the face 110 and the surface 308 is exaggerated so that the portion 124 of the facing 118 is shown with clarity. In practice, the surface 308 may be aligned snugly with the face 110.

Alternatively, an installer adheres the portion 138 of the facing 118 to a facing 148 of the fibrous insulation batt 800. In doing so, the installer may first remove a backing layer (e.g., paper) from adhesive material that is attached or applied to the surface 144 of the portion 138. Additionally, the installer may adhere the adhesive material on the surface 144 to the facing 148. Similarly, the installer may adhere the portion 146 (e.g., covered with adhesive material) to the portion 134 of the facing 118. In doing so, the installer may first remove a backing layer (e.g., paper) from adhesive material that is attached or applied to the portion 146 and apply the portion 146 to a surface 142.

The person of ordinary skill in the art will appreciate, however, that the order of operations of the methods described herein can be varied. For example, in certain embodiments of the methods described herein, the attaching the third portion of the facing to the first rafter is performed before the placing of the portion of the second face of the body of fibrous insulation that is between the first slit and the fourth face such that the portion of the second face faces a roof deck. Such a method is shown in schematic view in FIG. 11. The third portion of the facing (i.e., the portion of the facing on the side of the body distal to the slit) is first attached as indicated by the small arrow. Notably, the first section is folded over and the attachment is made on the surface of the first section that will lay against the second section in the installed state. The rest of the fibrous insulation batt can hang down, unattached, giving the installer the ability to get a hammer tacker or other tool into the folded-over region to attach the first section. Then, the body of fibrous insulation is swung up into the space between the rafters, with the portion between the slit and the third face of the body being compressed as described above. Finally, the second portion of the facing is attached to the rafter on its side distal to the body of fibrous insulation. When the second portion includes a folded-over first section, the attachment can be made in the folded-over portion such that the fastener (e.g., tack or staple) goes through two layers of the facing, as indicated by the arrow in the figure. In this embodiment, however, there need not be a folded-over first section of the second portion of the facing.

And in other embodiments the attaching the second portion of the facing to the first rafter is performed before the placing of the portion of the second face of the body of fibrous insulation that is between the first slit and the fourth face such that the portion of the second face faces a roof deck. Here, the second portion of the facing is attached to a rafter on the opposite side from where the body of fibrous insulation will fit. The body of fibrous insulation is swung up and compressed, then the folded-over first section of the third portion of the facing is attached. The installer would likely need to push on the body of insulation to compress it temporarily to get physical access to the folded-over first section of the third portion of the facing; as many common insulation materials are relatively compressible, this is a viable installation method in many cases.

It will be apparent to those skilled in the art that various modifications and variations can be made to the processes and devices described here without departing from the scope of the disclosure. Thus, it is intended that the present disclosure cover such modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.

Fibrous Insulation Batts Having One Or More Slits And Methods For Installing Them

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