Insulated Cover System

FIELD OF THE DISCLOSURE

The present disclosure relates to construction devices and, more particularly, to construction devices for buildings.

BACKGROUND

To reduce energy consumption, building codes have been evolving to require more insulation to form the building thermal envelope. The primary area of heat loss that requires the most insulation is the ceiling below the unconditioned attic space. Building codes in many areas of the country now require an R-value of 60 in attics.

Many homeowners utilize their attics for storage space or HVAC systems and install attic pull-down ladders for access. The area immediately above the attic pull-down ladder is difficult to adequately insulate because access is necessary through the ceiling opening when the attic pull-down ladder is in the deployed position. Thus, loose or flexible insulation that is generally installed in the rest of the attic cannot be installed over the attic pull-down ladder because it is not easily moveable and would collapse into the opening when the attic pull-down stairs are deployed. This attic access area is generally approximately 2 feet by 4 feet and is only covered by ¼ inch plywood, providing an inadequate thermal barrier with an energy leakage resulting in an estimated 20% increase in energy costs. In addition, building codes require the attic access point to be insulated to the same level as the rest of the attic, with few exceptions. As a result, builders may be increasingly more hesitant to install attic pull-down stairs, instead opting to install scuttle holes since the smaller opening is easier to insulate.

As codes evolve to require more insulation in the attic, solutions to adequately insulate the space above the attic pull-down stairs are becoming bulkier and heavier. Attempts by various companies to create insulated covers to minimize thermal loss are often too difficult to use because they require an individual to lift the enclosure on and off while balancing on the attic pull-down ladder. This leads to a safety problem since it requires the individual to remove both hands from the ladder which can lead to serious injury by falling off the ladder. Many times, these products often get tossed aside in the attic for convenience and are never used as intended. Companies are therefore forced to make the decision to create a product that is either light enough to safely move, or adequately insulated to meet code, but not both.

SUMMARY

It is an object of various embodiments of this invention to provide a safer means of insulating the attic pull-down ladder while meeting the latest code requirements for insulation R-value. By automating the maneuvering of the insulated enclosure, occupants will be able to always keep two hands on the attic pull-down ladder to safely access the attic.

An exemplary embodiment of the present invention comprises a stationary rectangular rigid frame having length and width dimensions substantially matching the length and width dimensions of the attic pull-down ladder frame, fitting between adjacent attic structural members, with an insulated cover made of rigid insulating material such as extruded polystyrene or polyisocyanurate panel having a high R-value, a weatherstrip gasket to form a seal when covering the rectangular frame, and a linkage assembly comprising two components, such as sets of steel bar linkages with rollers, brackets and bolts for attachment to the attic pull-down ladder assembly. In an exemplary embodiment, the insulated cover system can be universally used in attics with or without sheathed flooring, with new or existing attic pull-down ladders, with differing types or depths of surrounding insulation, and able to fit entirely between attic structural members such as trusses or rafters so as not to interfere. In other embodiments, the insulated cover may comprise a hinge, dividing the cover into two sections, thereby allowing the cover to fold for lower clearance attic spaces.

Exemplary embodiments provide an insulated cover system to seal a ceiling access to an attic space having attic insulation of a certain fill depth, the insulated cover system comprising an insulated cover movable from a closed position to an open position, and having an interior surface and an exterior surface, the closed position sealing the ceiling access and the open position exposing the ceiling access. The insulated cover system further comprises a rigid frame having a length, width, and height forming a rectangular aperture and having two sides and front and back ends, each said side forming a rectangle of said length and height, and the front and back ends each forming a rectangle of said width and height, said width and length configured to couple with a ladder assembly, said height configured to substantially match the level of the attic insulation fill depth, the insulated cover hingedly coupled to said back end via a hinge coupled to said insulation cover and said rigid frame back end. The insulated cover system further comprises a linkage assembly having two linkage assembly components, each linkage assembly component having two or more sections coupled by a fastening mechanism and first and second ends, the second end of each linkage assembly component adapted to slidably contact the insulated cover, the first end of each linkage assembly component pivotally coupled to the ladder assembly, wherein as the ladder assembly moves from a stored position to a deployed position, the pivotally coupled linkage assembly components move, which in slidable contact with the insulated cover, causes movement of the insulated cover from the closed position to the open position.

Other objects, features, and advantages will be apparent to persons of ordinary skill in the art from the following detailed description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and/or other exemplary features and advantages of the preferred embodiments of the present disclosure will become more apparent through the detailed description of exemplary embodiments thereof with reference to the accompanying drawings, in which:

FIG. 1 depicts a perspective view of an insulated cover system in accordance with an embodiment of the present disclosure;

FIG. 2 depicts a rear elevation view of an insulated cover system in an open position in accordance with an embodiment of the present disclosure;

FIG. 3 depicts a side cross-sectional view of an insulated cover system in an open position in accordance with an embodiment of the present disclosure;

FIG. 4 depicts a perspective view of an insulated cover system in a closed position in accordance with an embodiment of the present disclosure;

FIG. 5 depicts a rear elevation view of an insulated cover system in a closed position in accordance with an embodiment of the present disclosure;

FIG. 6 depicts a side cross-sectional view of an insulated cover system in a closed position in accordance with an embodiment of the present disclosure;

FIG. 7 depicts a perspective view of an insulated cover system in a mostly open position in accordance with an embodiment of the present disclosure;

FIG. 8 depicts a rear elevation view of an insulated cover system in a mostly open position in accordance with an embodiment of the present disclosure; and

FIG. 9 depicts a side cross-sectional view of an insulated cover system in a mostly open position in accordance with an embodiment of the present disclosure.

Throughout the drawings, like reference numbers and labels should be understood to refer to like elements, features, and structures.

DETAILED DESCRIPTION

Exemplary embodiments of the present disclosure will now be described more fully with reference to the accompanying drawings. The matters exemplified in this description are provided to assist in a comprehensive understanding of various embodiments disclosed with reference to the accompanying figures. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope and spirit of the claimed inventions. Descriptions of well-known functions and constructions are omitted for clarity and conciseness. To aid in clarity of description, the terms “upper,” “lower,” “above,” “below,” “left” and “right,” as used herein, provide reference with respect to orientation of the accompanying drawings and are not intended to be limiting.

FIG. 1 depicts a perspective view of an insulated cover system in accordance with an embodiment of the present disclosure. Exemplary embodiments of the present disclosure feature an insulated cover system 5 that seals a ceiling access to an attic space that has attic insulation of a certain fill depth. The insulation fill depth is a function of the insulating quality of the insulation material and the R-value required by the local building authorities. The higher the R-value, the deeper the insulation must be in order to meet code requirements. Ceiling/attic access ports present a break in the attic insulation coverage and must be adequately insulated in order to prevent energy leakage and maintain code compliance. Accordingly, insulated cover 12 of embodiments of the insulated cover system 5 are insulated.

To achieve the required R-value, embodiments of insulated cover 12 can be made of rigid insulating material such as extruded polystyrene or polyisocyanurate panel having a high R-value. Such embodiments of insulated cover 12 can comprise a singular block of material or a series of laminated sections bonded together such that in aggregate the required R-value is obtained. Each laminated section may also be made of rigid insulating material such as extruded polystyrene or polyisocyanurate having a high R-value, or other suitable material that is known in the art. Insulated cover 12 has an exterior surface 12a and an interior surface 12b and can be moved from a closed position to an open position. When in the open position, access to the attic space is available; when in the closed position, ceiling access is sealed and continuity of attic insulation preserved.

Exemplary embodiments disclose the insulated cover 12 as having a weatherstrip gasket 36 mounted in substantial proximity to the perimeter of the interior surface 12b of insulated cover 12 to facilitate a sealing engagement when the insulation cover 12 is in a closed position. Embodiments disclose the insulated cover 12 as having a recessed outer periphery 28 along the interior surface 12b to further facilitate a sealing engagement and, in exemplary embodiments, receive the weatherstrip gasket 36. Embodiments disclose the insulated cover 12 as having one or more guide bars 40 mounted to the interior surface 12b of the insulated cover 12.

Insulated cover system 5 further comprises a rigid frame 10 that has a length, width, and height and forms a rectangular aperture via the interior. The length of rigid frame 10 is formed by first and second sides 10a, 10b and the width is formed by front end 10c and back end 10d, each side 10a, 10b forms a rectangle of said length and height, and front end 10c and back end 10d each form a rectangle of said width and height. In exemplary embodiments of the present disclosure, insulated cover 12 hingedly couples to the back end 10d of rigid frame 10 via one or more hinges 24. Rigid frame 10 is formed of preferably lightweight material, which may be made of durable wood, plastic, or other suitable material as would be known to those in the art and may be molded or monolithically formed or may comprise panels bonded or fastened on its connecting edges. The height of rigid frame 10 is configured to substantially match the level of the attic insulation fill depth, and in so doing attic insulation material is less likely to fall through the ceiling access, contaminating the lower space underneath the attic. Rigid frame 10 is configured to couple with the pull-down ladder frame 44 of a pull-down ladder assembly, substantially matching and mating with length and width of the same, via screw, bolt, tie or mending plate, or other manner as is known in the art.

The pull-down ladder assembly comprises pull-down ladder frame 44, pull-down ladder 16, and a ceiling panel 32 that is mounted to pull-down ladder 16. Pull-down ladder 16 couples to pull-down ladder frame 44 via hardware comprising first and second ladder lever arms 26 and pull-down ladder spring 20. A linkage assembly having first and second linkage assembly components 14 provides mechanical linkage to couple the insulated cover system 5 to the ladder assembly. Each first and second linkage component 14 of the linkage assembly is made of durable material, such as metal, and formed of two or more sections coupled together via a fastening mechanism 42, such as bolt and nut or rivet pin, and forming a first linkage end and second linkage end. Embodiments of the present disclosure provide the first linkage end of each first and second linkage component 14 to pivotally couple to the ladder assembly via a pivot connector 31. Exemplary embodiments provide pivot connector 31 to couple to ceiling panel 32; alternate embodiments provide pivot connector 31 to couple to pull-down ladder 16. The second linkage end of each first and second linkage component 14 is adapted to slidably contact the interior surface 12b of the insulated cover 12. Exemplary embodiments of the present disclosure provide a roller 22 mounted to the second linkage end of each first and second linkage component 14 to facilitate slidable contact of the first and second linkage assembly components 14 with the insulated cover 12, and mate with, when used, first and second guide bar 40 mounted to the interior surface 12b of the insulated cover 12. Each first and second linkage component 14 pivotally couples to the pull-down ladder frame 44 via pivot pin 30.

In operation, from a stored position, the pull-down ladder 16 is retrieved from the pull-down ladder assembly. As the pull-down ladder 16 is lowered to a deployed position, each second linkage end of each first and second linkage component 14, due to pivot pin 30, is caused to move in a upwardly direction and in so doing move the insulated cover 12 from a closed position to an open position, as each second linkage end of each first and second linkage component 14 slides along the interior surface 12b of insulated cover 12. In this manner, insulated cover 12 automatically opens as the pull-down ladder 16 is moved from a stored to a deployed position, thereby providing safe, hands-free access to the attic space.

FIG. 2 depicts a rear elevation view of an insulated cover system in an open position in accordance with an embodiment of the present disclosure. Pull-down ladder 16 is shown deployed with mounted ceiling panel 32 attached. Two parallel first and second ladder lever arms 26 couple pull-down ladder 16 to pull-down ladder frame 44 via pull-down ladder spring 20 (not shown). First and second linkage assembly components 14 provide mechanical linkage coupling insulated cover system 5 to the ladder assembly.

The embodiment of the present disclosure depicted in FIG. 2 provides rigid frame 10 coupled with pull-down ladder frame 44, substantially matching the length and width of the same, and pull-down ladder frame 44 installs between attic framing 34. The height of rigid frame 10 substantially matches the level of attic insulation fill depth 19 of attic insulation 18. Insulated cover 12 is shown in an open position with the exterior surface 12a in view. The depicted embodiment of FIG. 2 provides insulated cover 12 as hingedly coupled to rigid frame back end 10d via first hinge and second hinge 24, which in exemplary embodiments couple to the insulated cover 12 via first and second mounting plate 38. Other embodiments of the present disclosure utilize a single hinge or three or more hinges to hingedly couple insulated cover 12 to rigid frame back end 10d. First and second mounting plates 38 are coupled to insulated cover 12 by adhesive, screw, bolt, or other suitable method of coupling that is known in the art, and receive first and second hinges 24 via a mechanical fastener, such as screw, bolt, rivet or other fastener as known in the art. First and second hinges 24 couple to the rigid frame back end 10d via a mechanical fastener, such as screw, bolt, rivet or other fastener as known in the art. Embodiments of the present disclosure provide the first linkage end of each first and second linkage component 14 to pivotally couple to the ladder assembly via a pivot connector 31. Exemplary embodiments provide pivot connector 31 to couple to ceiling panel 32; alternate embodiments provide pivot connector 31 to couple to pull-down ladder 16.

FIG. 3 depicts a side cross-sectional view of an insulated cover system in an open position in accordance with an embodiment of the present disclosure. Pull-down ladder 16 is shown deployed with mounted ceiling panel 32 attached. First and second ladder lever arms 26 couple pull-down ladder 16 to pull-down ladder frame 44 via pull-down ladder spring 20, which helps maintain ladder 16 in the stored position when not in use.

The embodiment of the present disclosure depicted in FIG. 3 provides the first linkage component 14 of first and second linkage assembly components 14 of the linkage assembly that provide mechanical linkage to couple the insulated cover system 5 to the ladder assembly. Each first and second linkage component 14 of the linkage assembly is made of durable material, such as metal, and formed of two or more sections coupled together via a fastening mechanism 42, such as bolt and nut or rivet pin, and forming a first linkage end and second linkage end. Embodiments of the present disclosure provide the first linkage end of each first and second linkage component 14 to pivotally couple to the ladder assembly via a pivot connector 31. Exemplary embodiments provide pivot connector 31 to couple to ceiling panel 32; alternate embodiments provide pivot connector 31 to couple to pull-down ladder 16. The second linkage end of each first and second linkage component 14 is adapted to slidably contact the interior surface 12b of the insulated cover 12. The embodiment of the present disclosure depicted in FIG. 3 provides roller 22 mounted to the second linkage end of each first and second linkage component 14 to facilitate slidable contact of the first and second linkage assembly components 14 with the insulated cover 12, and mate with first and second guide bar 40 mounted to the interior surface 12b of the insulated cover 12. Each first and second linkage component 14 pivotally couples to the pull-down ladder frame 44 via pivot pin 30.

The embodiment of the present disclosure depicted in FIG. 3 provides rigid frame 10 coupled with pull-down ladder frame 44, substantially matching the length and width of the same, and pull-down ladder frame 44 installs between attic framing 34. The height of rigid frame 10 substantially matches the level of attic insulation fill depth 19 of attic insulation 18. Insulated cover 12 is shown in an open position with the exterior surface 12a normal to the sectional view. The depicted embodiment of FIG. 3 provides insulated cover 12 as hingedly coupled to rigid frame back end 10d via first and second hinges 24, which in exemplary embodiments couple to the insulated cover 12 via first and second mounting plates 38. First and second mounting plates 38 couple to the insulated cover 12 by adhesive, screw, bolt, or other suitable method of coupling that is known in the art, and receive first and second hinge 24 via a mechanical fastener, such as screw, bolt, rivet or other fastener as known in the art. First and second hinges 24 couple to the rigid frame back end 10d via a mechanical fastener, such as screw, bolt, rivet or other fastener as known in the art.

The embodiment of the present disclosure depicted in FIG. 3 provides the insulated cover 12 as having a recessed outer periphery 28 along the interior surface 12b to further facilitate a sealing engagement and, in exemplary embodiments, receive the weatherstrip gasket 36.

FIG. 4 depicts a perspective view of an insulated cover system in a closed position in accordance with an embodiment of the present disclosure. The embodiment of the present disclosure depicted in FIG. 4 provides rigid frame 10 of insulated cover system 5 coupled with pull-down ladder frame 44, substantially matching the length and width of the same. Insulated cover 12 is in a closed position with exterior surface 12a visible. The depicted embodiment of FIG. 4 provides insulated cover 12 as hingedly coupled to rigid frame back end 10d via first hinge and second hinge 24, which in exemplary embodiments couple to insulated cover 12 via first and second mounting plates 38. First and second mounting plates 38 are coupled to insulated cover 12 by adhesive, screw, bolt, or other suitable method of coupling that is known in the art, and receive first and second hinges 24 via a mechanical fastener, such as screw, bolt, rivet or other fastener as known in the art. First and second hinges 24 couple to the rigid frame back end 10d via a mechanical fastener, such as screw, bolt, rivet or other fastener as known in the art. The pull-down ladder assembly is shown in a stored position with ceiling panel 32 in a closed position.

FIG. 5 depicts a rear elevation view of an insulated cover system in a closed position in accordance with an embodiment of the present disclosure. The embodiment of the present disclosure depicted in FIG. 5 provides rigid frame 10 of insulated cover system 5 coupled with pull-down ladder frame 44, substantially matching the length and width of the same, and pull-down ladder frame 44 installs between attic framing 34. The height of rigid frame 10 substantially matches the level of attic insulation fill depth 19 of attic insulation 18. Insulated cover 12 is shown in a closed position. The depicted embodiment of FIG. 5 provides insulated cover 12 as hingedly coupled to rigid frame back end 10d via first and second hinges 24, which in exemplary embodiments couple to insulated cover 12 via first and second mounting plates 38. Other embodiments of the present disclosure utilize a single hinge or three or more hinges to hingedly couple insulated cover 12 to rigid frame back end 10d. First and second mounting plates 38 couple to insulated cover 12 by adhesive, screw, bolt, or other suitable method of coupling that is known in the art, and receive first and second hinges 24 via a mechanical fastener, such as screw, bolt, rivet or other fastener as known in the art. First and second hinges 24 couple to the rigid frame back end 10d via a mechanical fastener, such as screw, bolt, rivet or other fastener as known in the art. The pull-down ladder assembly is shown in a stored position with ceiling panel 32 in a closed position.

FIG. 6 depicts a side cross-sectional view of an insulated cover system in a closed position in accordance with an embodiment of the present disclosure. Pull-down ladder 16 is shown in a stored position with mounted ceiling panel 32 attached. First and second ladder lever arms 26 couple pull-down ladder 16 to pull-down ladder frame 44 via pull-down ladder spring 20, which helps maintain ladder 16 in the stored position.

The embodiment of the present disclosure depicted in FIG. 6 provides the first linkage component 14 of first and second linkage assembly components 14 of the linkage assembly that provides mechanical linkage to couple the insulated cover system 5 to the ladder assembly. Each first and second linkage component 14 of the linkage assembly is made of durable material, such as metal, and formed of two or more sections coupled together via a fastening mechanism 42, such as bolt and nut or rivet pin, and forming a first linkage end and second linkage end. Embodiments of the present disclosure provide the first linkage end of each first and second linkage component 14 to pivotally couple to the ladder assembly via a pivot connector 31. Exemplary embodiments provide pivot connector 31 to couple to ceiling panel 32; alternate embodiments provide pivot connector 31 to couple to pull-down ladder 16. The second linkage end of each first and second linkage component 14 is adapted to slidably contact the interior surface 12b of the insulated cover 12. The embodiment of the present disclosure depicted in FIG. 6 provides a roller 22 mounted to the second linkage end of each first and second linkage component 14 to facilitate slidable contact of the first and second linkage assembly components 14 with the insulated cover 12, and mate with first and second guide bar 40 mounted to the interior surface 12b of the insulated cover 12. Each first and second linkage component 14 pivotally couples to the pull-down ladder frame 44 via pivot pin 30.

The embodiment of the present disclosure depicted in FIG. 6 provides rigid frame 10 coupled with pull-down ladder frame 44, substantially matching the length and width of the same, and pull-down ladder frame 44 installs between attic framing 34. The height of rigid frame 10 matches the level of attic insulation fill depth 19 of attic insulation 18. Insulated cover 12 is shown in a closed position with the exterior surface 12a normal to the sectional view. The depicted embodiment of FIG. 6 provides insulated cover 12 as hingedly coupled to rigid frame back end 10d via first and second hinges 24 which, in exemplary embodiments, couples to insulated cover 12 via first and second mounting plates 38. First and second mounting plates 38 couple to insulated cover 12 by adhesive, screw, bolt, or other suitable method of coupling that is known in the art, and receive first and second hinge 24 via a mechanical fastener, such as screw, bolt, rivet or other fastener as known in the art. First and second hinges 24 couple to the rigid frame back end 10d via a mechanical fastener, such as screw, bolt, rivet or other fastener as known in the art.

The embodiment of the present disclosure depicted in FIG. 6 provides the insulated cover 12 as having a recessed outer periphery 28 along the interior surface 12b to further facilitate a sealing engagement and, in exemplary embodiments, receive the weatherstrip gasket 36.

FIG. 7 depicts a perspective view of an insulated cover system in a mostly open position in accordance with an embodiment of the present disclosure. In some attics, the roof line or structural members are low, resulting in reduced or low vertical clearance space. In such attic constructions, there may not be adequate space for insulated cover 12 to fully open when pull-down ladder 16 is fully deployed. To accommodate such low clearance space attic constructions, exemplary embodiments of the present disclosure provide a segmented insulated cover 12 having two or more segments that can fold while opening during pull-down ladder 16 deployment, thus the required vertical clearance is reduced for full opening of insulated cover 12. Each segment of Insulated cover 12 is coupled to an adjacent segment via one or more cover hinges 46, and each segment has an exterior surface 12a and an interior surface 12b and folds as insulated cover 12 is moved from a closed position to an open position. When in the open position, access to the attic space is available; when in the closed position, ceiling access is sealed and continuity of attic insulation preserved. The exemplary embodiment of the present disclosure depicted in FIG. 7 provides an insulated cover 12 having two segments in a partially folded state while pull-down ladder 16 is in the mostly deployed position.

To achieve the required insulation R-value, embodiments of the insulated cover 12 segments can be made of rigid insulating material such as extruded polystyrene or polyisocyanurate panel having a high R-value. Such embodiments of insulated cover 12 segments can comprise a singular block of material or a series of laminated sections bonded together such that in aggregate the required R-value is obtained. Each laminated section may also be made of rigid insulating material such as extruded polystyrene or polyisocyanurate having a high R-value, or other suitable material that is known in the art.

Exemplary embodiments disclose the insulated cover 12 as having a weatherstrip gasket 36 mounted in substantial proximity to the perimeter of the interior surface 12b of insulated cover 12 along one or more segments to facilitate a sealing engagement when the insulation cover 12 is in a closed position. Embodiments disclose the insulated cover 12 as having a recessed outer periphery 28 along the interior surface 12b of each segment to further facilitate a sealing engagement and, in exemplary embodiments, receive the weatherstrip gasket 36. Embodiments disclose the insulated cover 12 as having a first and second guide bars 40 mounted to the interior surface 12b of the insulated cover 12.

Insulated cover system 5 further comprises a rigid frame 10 that has a length, width, and height and forms a rectangular aperture via the interior. The length of rigid frame 10 is formed by first and second sides 10a, 10b and the width is formed by front end 10c and back end 10d, each side 10a, 10b forms a rectangle of said length and height, and front end 10c and back end 10d each form a rectangle of said width and height. In exemplary embodiments of the present disclosure, insulated cover 12 hingedly couples to the back end 10d of rigid frame 10 via one or more hinges 24, which, in exemplary embodiments, couple to insulated cover 12 via one or more mounting plates 38. Said one or more hinges 24 couple to the rigid frame back end 10d via a mechanical fastener, such as screw, bolt, rivet or other fastener as known in the art. Rigid frame 10 is formed of preferably lightweight material, which may be made of durable wood, plastic, or other suitable material as would be known to those in the art and may be molded or monolithically formed or may comprise panels bonded or fastened on its connecting edges. The height of rigid frame 10 is configured to substantially match the level of the attic insulation fill depth, and in so doing attic insulation material is less likely to fall through the ceiling access, contaminating the lower space underneath the attic. Rigid frame 10 is configured to couple with the pull-down ladder frame 44 of a pull-down ladder assembly, substantially matching and mating with length and width of the same, via screw, bolt, tie or mending plate, or other manner as is known in the art.

The pull-down ladder assembly comprises pull-down ladder frame 44, pull-down ladder 16, and a ceiling panel 32 that is mounted to pull-down ladder 16. Pull-down ladder 16 couples to pull-down ladder frame 44 via hardware comprising two parallel first and second ladder lever arms 26 and pull-down ladder spring 20 (not shown). A linkage assembly having first and second linkage assembly components 14 provides mechanical linkage to couple the insulated cover system 5 to the ladder assembly. Each first and second linkage component 14 of the linkage assembly is made of durable material, such as metal, and formed of two or more sections coupled together via a fastening mechanism 42, such as bolt and nut or rivet pin, and forming a first linkage end and second linkage end. Embodiments of the present disclosure provide the first linkage end of each first and second linkage component 14 to pivotally couple to the ladder assembly via a pivot connector 31. Exemplary embodiments provide pivot connector 31 to couple to ceiling panel 32; alternate embodiments provide pivot connector 31 to couple to pull-down ladder 16. The second linkage end of each first and second linkage component 14 is adapted to slidably contact the interior surface 12b of each segment of the insulated cover 12. Exemplary embodiments of the present disclosure provide a roller 22 mounted to the second linkage end of each first and second linkage component 14 to facilitate slidable contact of the first and second linkage assembly components 14 with the insulated cover 12, and mate with, when used, first and second guide bar 40 mounted to the interior surface 12b of the insulated cover 12. Each first and second linkage component 14 pivotally couples to the pull-down ladder pull-down ladder frame 44 via pivot pin 30 (not shown).

FIG. 8 depicts a rear elevation view of an insulated cover system in a mostly open position in accordance with an embodiment of the present disclosure. Pull-down ladder 16 is shown deployed with mounted ceiling panel 32 attached. Two parallel first and second ladder lever arms 26 couple pull-down ladder 16 to pull-down ladder frame 44 via pull-down ladder spring 20 (not shown). First and second linkage assembly components 14 provide mechanical linkage coupling of the ladder assembly to insulated cover system 5. Each first and second linkage component 14 of the linkage assembly is made of durable material, such as metal, and formed of two or more sections coupled together via a fastening mechanism 42, such as bolt and nut or rivet pin, and forming a first linkage end and second linkage end. Embodiments of the present disclosure provide the first linkage end of each first and second linkage component 14 to pivotally couple to the ladder assembly via a pivot connector 31. Exemplary embodiments provide pivot connector 31 to couple to ceiling panel 32; alternate embodiments provide pivot connector 31 to couple to pull-down ladder 16.

The embodiment of the present disclosure depicted in FIG. 8 provides rigid frame 10 coupled with pull-down ladder frame 44, substantially matching the length and width of the same, and pull-down ladder frame 44 installs between attic framing 34. The height of rigid frame 10 substantially matches the level of attic insulation fill depth 19 of attic insulation 18. Insulated cover 12 is shown in a mostly open position with the exterior surface 12a in view. The depicted embodiment of FIG. 8 provides insulated cover 12 hingedly coupled to rigid frame back end 10d via first and second hinges 24, which in exemplary embodiments couple to insulated cover 12 via first and second mounting plates 38. Other embodiments of the present disclosure utilize a single hinge or three or more hinges to hingedly couple insulated cover 12 to rigid frame back end 10d. First and second mounting plates 38 couple to insulated cover 12 by adhesive, screw, bolt, or other suitable method of coupling that is known in the art, and receive first and second hinges 24 via a mechanical fastener, such as screw, bolt, rivet or other fastener as known in the art. First and second hinges 24 couple to the rigid frame back end 10d via a mechanical fastener, such as screw, bolt, rivet or other fastener as known in the art.

FIG. 9 depicts a side cross-sectional view of an insulated cover system in a mostly open position in accordance with an embodiment of the present disclosure. Pull-down ladder 16 is shown deployed with mounted ceiling panel 32 attached. First and second ladder lever arms 26 couple pull-down ladder 16 to pull-down ladder frame 44 via pull-down ladder spring 20, which helps maintain ladder 16 in the stored position when not in use.

Exemplary embodiments of the present disclosure provide a segmented insulated cover 12 having two or more segments that can fold while opening during pull-down ladder 16 deployment, thus the required vertical clearance is reduced for full opening of insulated cover 12. Each segment of insulated cover 12 is coupled to an adjacent segment via one or more cover hinges 46, and each segment has an exterior surface 12a and an interior surface 12b and folds as insulated cover 12 is moved from a closed position to an open position. When in the open position, access to the attic space is available; when in the closed position, ceiling access is sealed and continuity of attic insulation preserved. The exemplary embodiment of the present disclosure depicted in FIG. 9 provides an insulated cover 12 having two segments in a partially folded, mostly open state while pull-down ladder 16 is in the mostly deployed position.

The embodiment of the present disclosure depicted in FIG. 9 provides the first linkage component 14 of first and second linkage assembly components 14 of the linkage assembly that provides mechanical linkage to couple the insulated cover system 5 to the ladder assembly. Each first and second linkage component 14 of the linkage assembly is made of durable material, such as metal, and formed of two or more sections coupled together via a fastening mechanism 42, such as bolt and nut or rivet pin, and forming a first linkage end and second linkage end.

Embodiments of the present disclosure provide the first linkage end of each first and second linkage component 14 to pivotally couple to the ladder assembly via a pivot connector 31. Exemplary embodiments provide pivot connector 31 to couple to ceiling panel 32; alternate embodiments provide pivot connector 31 to couple to pull-down ladder 16. The second linkage end of each first and second linkage component 14 is adapted to slidably contact the interior surface 12b of one or more segments of insulated cover 12. The embodiment of the present disclosure depicted in FIG. 9 provides a roller 22 mounted to the second linkage end of each first and second linkage component 14 to facilitate slidable contact of the first and second linkage assembly components 14 with the insulated cover 12 along one or more segments, and mate with first and second guide bars 40 mounted to the interior surface 12b of the insulated cover 12. Each first and second linkage component 14 pivotally couples to the pull-down ladder frame 44 via pivot pin 30.

The embodiment of the present disclosure depicted in FIG. 9 provides rigid frame 10 coupled with pull-down ladder frame 44, substantially matching the length and width of the same, and pull-down ladder frame 44 installs between attic framing 34. The height of rigid frame 10 substantially matches the level of attic insulation fill depth 19 of attic insulation 18. Insulated cover 12 is depicted in FIG. 9 as two segments in a mostly open position with the exterior surface 12a normal to the sectional view, with one segment hingedly coupled to rigid frame back end 10d via first and second hinges 24 which in exemplary embodiments couple to insulated cover 12 via first and second mounting plates 38. First and second mounting plates 38 couple to insulated cover 12 by adhesive, screw, bolt, or other suitable method of coupling that is known in the art, and receive first and second hinges 24 via a mechanical fastener, such as screw, bolt, rivet or other fastener as known in the art. First and second hinges 24 couple to the rigid frame back end 10d via a mechanical fastener, such as screw, bolt, rivet or other fastener as known in the art.

The embodiment of the present disclosure depicted in FIG. 9 provides the insulated cover 12 segments as having a recessed outer periphery 28 along the interior surface 12b to further facilitate a sealing engagement and, in exemplary embodiments, receive weatherstrip gasket 36.

Exemplary embodiments of the present disclosure provide individual components of the insulated cover system in a disassembled or partially disassembled collection to form an insulated cover system kit having component parts capable of being packaged in a disassembled form and of being assembled into an insulated cover system to seal a ceiling access to an attic space having attic insulation of a certain fill depth. The insulated cover system kit comprises an insulated cover system to seal a ceiling access to an attic space having attic insulation of a certain fill depth, the insulated cover system comprising an insulated cover movable from a closed position to an open position, and having an interior surface and an exterior surface, the closed position sealing the ceiling access and the open position exposing the ceiling access. The insulated cover system kit further comprises a rigid frame having a length, width, and height forming a rectangular aperture and having two sides and front and back ends, each said side forming a rectangle of said length and height, and the front and back ends each forming a rectangle of said width and height, said width and length configured to couple with a ladder assembly, said height configured to substantially match the level of the attic insulation fill depth, the insulated cover hingedly coupled to said back end via a hinge coupled to said insulation cover and said rigid frame back end. The insulated cover system kit further comprises a linkage assembly having two linkage assembly components, each linkage assembly component having two or more sections coupled by a fastening mechanism and first and second ends, the second end of each linkage assembly component adapted to slidably contact the insulated cover, the first end of each linkage assembly component pivotally coupled to the ladder assembly, wherein as the ladder assembly moves from a stored position to a deployed position, the pivotally coupled linkage assembly components move, which in slidable contact with the insulated cover, causes movement of the insulated cover from the closed position to the open position.

While the invention has been described in connection with preferred embodiments, it will be understood by those of ordinary skill in the art that other variations and modifications of the preferred embodiments described above may be made without departing from the scope of the invention. Other embodiments will be apparent to those of ordinary skill in the art from a consideration of the specification or practice of the invention disclosed herein.

Insulated Cover System

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CROSS-REFERENCE TO RELATED APPLICATION