This invention relates to the progressive application of flexible sheet material, such as blanket insulation, to the purlins of a roof during the progressive construction of a roof of an industrial building. More particularly, the invention involves a plurality of carriages for carrying reels of flexible sheet material in two rows of carriages along adjacent purlins of a roof and dispensing the sheet material onto the purlins in response to the movement of the carriages.
Industrial buildings have roof structures that typically include inclined rafter beams that extend parallel to each other and are sloped from the eaves up to the ridge of the building structure. Horizontally oriented purlins are mounted on the rafters and extend parallel to each other in a direction normal to the rafters. The purlins are supported by the rafters and flexible sheet material, such as blanket insulation, is spread over the purlins. The lengths of the blankets can extend either normal to or parallel to the purlins. Hard roof panels are applied on the insulation and are connected through the insulation to the purlins.
In recent years, flexible insulation blankets have been applied to industrial buildings by orienting the lengths of the blankets parallel to the purlins and placing the opposed side edges of the blankets on the tops of the purlins so that each blanket spans the space between adjacent purlins. This procedure of applying the flexible sheet material to the purlins during the construction of a roof has the advantage of mounting the edges of the sheets on top of the purlins so that there are no seams between adjacent sheets that are directly exposed to the space below the purlins of the roof. This helps reduce the penetration of heat, moisture and other items carried by the environment within the building through the seams between the sheets to the roof panels.
In order to apply the blanket insulation to the purlins of the roof structure, a reel support carriage such as those disclosed in U.S. Pat. Nos. 3,559,914, 3,969,863, 4,075,807, 4,147,003, and 4,967,535 can be mounted on the purlins of the roof for supporting one or more of the reels of blanket insulation. The reel support carriage, sometimes known as a “roll stand,” is guided by adjacent ones of the purlins and supports a supply of flexible sheet material, such as a reel of blanket insulation, above the space between the adjacent purlins.
Usually, a plurality of the reel support carriages are mounted on the purlins in two rows, with the first or forward row of carriages mounted over alternate spaces between the purlins and the second or rear row of carriages mounted over the other alternate spaces between the purlins. The workers stand on the hard roof panels that already have been applied to the purlins and push the carriages with push bars farther along the purlins to apply the blanket insulation as the blankets unroll themselves in response to the motion of the carriages. When the carriages have been pushed far enough away from the last applied roof panels, additional roof panels are applied to the purlins in the space between the last installed roof panels and the second row of carriages, and the procedure continues.
While the above noted process is suitable for applying blanket insulation to the purlins of a roof structure, other types of flexible sheet material can be applied in the same manner. For example, reflective sheet material, phase change material, and virtually any type of flexible sheet material that can be mounted on a carriage and progressively paid out from its supply and applied to the purlins can be installed in this manner.
One of the problems that is encountered in applying sheet material, such as fiberglass blanket insulation, to the purlins of industrial buildings is that the sheet material is suspended from its side edges that are applied to the tops of the purlins and the center portions of the sheets have no support and tend to sag between the purlins before the hard roof panels can be applied to the roof. Once the hard roof panels are applied by the insertion of fasteners through the hard roof panels down through the edges of the insulation sheets into the purlins, the sheet material becomes stabilized in its shape. If during the installation process the central portion of the sheet material is supported, the sagging of the central portion of the sheet material will be minimized after it has been installed. However, when the carriages that support the reel of sheet material are moved away from the previously installed hard roof panels, the insulation tends to sag downwardly between the purlins due to its lack of support before the roof panels are attached. This problem is affected by wind, the flexibility of the sheet material, the performance of the reel support carriages and the lack of experience and capability of the installers.
One of the solutions used in the industry to avoid the sagging of the sheet material between the purlins during the installation of a roof of an industrial building is to install metal bands in the roof structure before the sheet material is installed. The metal bands extend parallel to and between adjacent purlins at the desired height of the sheet material, thereby providing support for the sheet material when laid on the purlins and avoiding the sagging as described above. While the use of the support bands has reduced the problem of sagging insulation in the spaces between the purlins, the bands are expensive and are expensive to install at the building site. Moreover, the support bands have little function after the roof has been completely installed since the fasteners and hard roof panels adequately support the sheet material at the edges of the sheets and prevent excess sagging of the sheet material between the purlins. Further, the bands tend to compact the insulation more than when the insulation is suspended between the purlins without the use of bands. Compacting the insulation results in reduced insulating capacity of the blankets.
I developed an insulation carriage that includes a sheet support that extends from the carriage back beneath the previously paid out segment of sheet material toward the last applied hard roof panels, as disclosed in U.S. Pat. No. 4,967,535. The sheet supports of the carriages of the '535 patent support the sheet material extending from the second row of carriages that are close to the previously applied to the roof panels, but do not adequately support the sheet material when the carriages are moved away from the roof panels, particularly the first row of carriages that are always farther away from the roof panels. Also, the sheet supports of the '535 patent must be installed on all of the carriages and the carriages must carry the weight of the sheet supports, making the carriages heavier and more bulky than is desirable. And the sheet support of one carriage sometimes does not support its sheet at the same level as the others.
Thus, it can be seen that it would be desirable to provide a sheet support system for use in the construction of a roof of an industrial building that precisely holds the segment of the sheet material extending from a roof insulation support carriage back to the previously installed hard roof panels so that the sheet material is properly installed without the likelihood of undesirable sagging of the sheet material between the purlins once the roof structure has been completed. It is through the provision of such that the present invention is primarily directed.
The present invention involves a method and apparatus for applying flexible sheet material, such as blanket insulation, to the purlins of a roof structure of an industrial building, whereby the sheet material is applied parallel to the purlins with the edges of the sheets resting on the top surfaces of the purlins and fastened to the purlins by the hard roof panels and their fasteners.
A plurality of roof insulation support carriages are mounted on the purlins in two rows, a first or forward row of carriages with these carriages mounted over alternated spaces between the purlins, and a second or rear row of carriages mounted over the other alternate spaces between the purlins. A sheet support is connected to each rear carriage and is supported by the purlins on which the carriage is mounted, and moves in unison with the carriage as the carriage is advanced forwardly along the purlins.
The sheet support, in one embodiment of the invention, surrounds the carriage and has a forward segment that is pushed by the carriage when the carriage is advanced. The sheet support includes a rear segment that is displaced rearwardly from its carriage and spans the space between the adjacent purlins on which the carriage is mounted, and slides with the movement of the carriage on the purlins beneath the paid out segment of flexible sheet material extending from the carriage back to the previously installed roof panels. In addition, the sheet support has side segments that are positioned on opposite sides of the carriage and extend into the spaces of the next adjacent purlins to perform the same purpose in those spaces. Rear segments and side segments of the sheet support provide support for the flexible sheet material at a distance rearwardly from the carriage, that can be positioned immediately adjacent the expected position of the next to be installed hard roof panel.
In one embodiment of the invention, the rear segment and side segments of the sheet support form elongated slots therebetween that register with the purlins, so that the rear segment and side segments of the sheet support can extend all the way back from the carriage into the space where the next hard roof panel is to be installed, so that even as the panel is being fastened down to the purlins, the sheet support is in its supportive position beneath the flexible sheet material and beneath the panel that is being installed. In the meantime, the sheet support is resting on the purlins so that the exact desired height of the rear segment and side segments of the sheet support is attained, thereby providing optimum support for the flexible sheet material as it is being installed in the roof structure.
Typically, a plurality of the roof insulation support carriages would be mounted on the roof structure at one time, in two lines or rows, with the first or front row of carriages mounted on the purlins of every other space between the purlins, and a second or rear row of carriages mounted on the purlins at the other alternate spaces between the purlins. The sheet supports are required only on the rear row of carriages since the side segments of the sheet supports extend out into the alternate spaces over which the forward carriages are mounted. This has the advantage of utilizing only one-half the number of sheet supports as well as having the sheet supports of one size and configuration to serve the entire roof structure. Also, since the sheet supports are used with the second row of carriages, the sheet supports are used close to the installers that stand on the roof panels, thereby requiring less effort to handle the sheet supports during installing and using the sheet supports on the purlins.
Thus, it is an object of this invention to provide a sheet support for use with a roof insulation support carriage for accurately and expediently applying flexible sheet material, such as blanket insulation, to the purlins of a roof structure.
Another object of this invention is to provide an improved sheet support that is suitable for use with the second row of roof insulation support carriages that provides accurate support for flexible sheet material being applied to the roof structure by the carriages in both the first and second rows of carriages.
Another object of the invention is to provide a plurality of sheet support carriages in first and second rows of carriages on a roof structure and sheet supports associated with the second row of carriages that support the sheets extending from all of the carriages back to the previously installed roof panels.
Another object of the invention is to provide a combination of a carriage for applying sheet material to purlins of a roof of an industrial building and a sheet support for accurately supporting the sheet material paid out from the carriage at the desired level to avoid sagging of the sheet material between the purlins.
Another object of the invention is to provide a sheet support for an insulation carriage that supports the segment of sheet material extending from the carriage back to the previously installed roof panels, with the sheet supports resting on the purlins and functioning to support the sheets extending from both the first row and the second row of carriages.
Yet another object of the invention is to provide an improved method of installing sheet material, such as blanket insulation, to the purlins of a roof of an industrial building.
Other objects, features and advantages of this invention will become apparent upon reading the following specification when taken in conjunction with the accompanying drawings.
Referring now in more detail to the drawings, in which like numerals indicate like parts throughout the several views,
The roof insulation support carriage 10 includes a rectangular support frame 20 and a vertical reel support 22 mounted on and extending upwardly from the frame. The support frame 20 includes longitudinally extending side bars 24A and 24B and laterally extending cross bars 26A and 26B that form the rectangular shape of the support frame, and cross roller 28 that is rotatably supported by its axle to side bars 24A and 24B. The support frame 20, including the cross roller 28, is of sufficient size so as to span and rest upon adjacent ones of the purlins 14 and 16. A frame guide 29 is mounted to forward cross bar 26B of the support frame 20 for engagement with one of the purlins 14, by engaging the edge of the upper flange 19 of the purlin, for guiding the carriage along the lengths of the purlins 14 and 16. An additional frame guide can be used to engage the other purlin, if desired.
Sheet support 22 includes upright stanchions 30A and 30B mounted at their lower ends to the side bars 24A and 24B, respectively. Reel support axle 32 is mounted at its opposite ends to the upper ends of the stanchions, and a reel 34 of sheet material, such as blanket insulation, is mounted on the reel support axle 32. The free end portion 35 of the sheet material is paid out from the reel 34 and moved downwardly and about the cross roller 28, and then extended rearwardly on the upper flanges 19 of the adjacent purlins 14 and 16, as shown.
As shown in
A sheet support 50 is mounted about the support frame 20 of each support carriage 10 in the second row of carriages, and the sheet support 50 includes a forward segment 52, a rear segment 54, and opposed side segments 56 and 58, all of which generally form a rectangular shape. The distance between the forward segment 52 and rear segment 54 is sufficient to span the fore and aft dimension of the support carriage 10. Connection span 59 is formed in the forward segment 52 that is recessed toward the rear segment 54, and which is pivotally attached by a hinge 60 to the forward cross bar 26B of the support frame 20.
The sheet support 50 is formed of tubular metal, such as aluminum and is formed in a closed loop in a single plane. In the embodiment of
As shown in
It will be noted that the side segments 56 and 58 of the sheet supports extend beyond their purlins, into the next adjacent space, such as space 60B of the purlins, behind the forward roof insulation support carriage 10B. This presents support for all of the segments of sheet material that are paid out from the roof insulation support carriages mounted over all of the spaces between the purlins.
As illustrated in
In the process of applying the roof to the purlins, the installers push the carriages 10A, 10B and 10C farther along the purlins a distance sufficient to install another roof panel 37 between the previously installed panel and the carriages. The sheet supports 50A and 50C as well as the upper flanges of the purlins hold the sheet material extending from both the first and second rows of carriages in the desired, non-sagging configuration while the next roof panels are installed with their fasteners 63.
As illustrated in
As shown in
The operation of the sheet supports 70D, 70E and 70F is similar to that of the operation of the sheet supports 50A and 50C of
An additional strengthening strut 83 is connected at its ends to the side segments 76 and 78 and intermediate its ends to the U-shaped bends 85 and 86 formed between the side segments 76 and 78 and the rear segment 74. This stabilizes the rear and side segments 74, 76 and 78 of the sheet supports 70.
The dog leg 81 of sheet support 70 allows the sheet material to be installed without excess compression of the sheet material against the rear segment 74 and side segments 76, 78 and allows rear and side segments of the sheet support to slide out from under the sheet material without excessive friction, to avoid scratching, tearing or stretching the sheet material.
As with the embodiment of
The roof insulation support carriage 10 can be of the type described and illustrated in my prior application Ser. No. 10/096,119, or in my prior patents U.S. Pat. Nos. 3,559,914, 4,147,003, 4,967,535, and others.
Although preferred embodiments of the invention has been disclosed in detail herein, it will be obvious to those skilled in the art that variations and modifications of the disclosed embodiments can be made without departing from the spirit and scope of the invention as set forth in the following claims.
This is a continuation-in-part of U.S. patent application Ser. No. 10/096,119, filed Mar. 8, 2002 now U.S. Pat. No. 6,672,024.
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Number | Date | Country | |
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20030167731 A1 | Sep 2003 | US |
Number | Date | Country | |
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Parent | 10096119 | Mar 2002 | US |
Child | 10132841 | US |