The present application claims priority to Australian Patent Application No. 2009905528, filed Nov. 11, 2009, which application is incorporated herein fully by this reference.
The present invention provides a material, methods of using the material, floor structures constructed using the material and tools used in the methods.
With increased concern about the sustainability and environmental impact of energy consumption, there has been an increased focus on the energy efficiency of buildings such as houses in order to reduce their energy requirements. In PCT/AU2004/001498, the applicant proposed an insulation material that could be rapidly installed when the floor of a building is built on a frame structure.
The present application relates to developments of that material and techniques for installation of the material.
In a first aspect, there is provided a material for installation over a plurality of regularly spaced joists to insulate a floor structure, the material having a plurality of spaced apart sets of linearly arranged holes extending across the width of the material, the holes intended to overly the joists so that once the material is in place, flooring material can be adhered to the joists through the holes, each set of linearly arranged holes allowing access to 50 to 98 percent of the length of the joist overlain by the set of holes.
In an embodiment, each set of linearly arranged holes allows access to 65 to 90 percent of the length of the joist overlain by the set of holes.
In an embodiment, the spacing of the sets of holes from one another is greater than the spacing of the joists such that, in use, the material between adjacent joists hangs below the top of the joists to define an insulating air gap between the material and the flooring material once the flooring material is installed.
In an embodiment, the material further comprises fold lines either side of each set of holes to enable the material to be formed into a rectangular trough.
In an embodiment, the material further comprises indicia either side of each set of holes to indicate where the material should be folded to be formed into a rectangular trough.
In an embodiment, said material is heat reflective or has a heat reflective layer.
In an embodiment, the holes are circular or oval such that the regions around the holes are held taut to lie flat against the joists.
In an embodiment, the material is formed into a roll so that it can be rolled out across the joists during installation.
In an embodiment, the material further comprises indicia set in from the edge of the material indicating a desirable overlap with a neighbouring length of the material.
In a second aspect, there is provided a method of installing a floor on a plurality of regularly spaced joists, the method comprising:
In an embodiment, each set of linearly arranged holes allows access to 65 to 90 percent of the length of the joist overlain by the set of holes.
In an embodiment, the method further comprises attaching the material to the joists.
In an embodiment, the method comprises applying the adhesive in continuous beads extending along the length of the joists after locating the material in place.
In an embodiment, the spacing of the sets of holes from one another is greater than the spacing of the joists such that, in use, the material between adjacent joists hangs below the top of the joists to define an insulating air gap between the material and the flooring material once the flooring material is installed.
In an embodiment, the method comprises folding the material between each set of joists to define an air gap having a substantially rectangular cross-section.
In an embodiment, the method comprises folding the material along indicia indicating where the material should be folded.
In an embodiment, the method comprises folding the material with a tool having a substantially u-shaped cross-section by locating an open end of the tool over the material where it overlies the joists and pressing downwards to form the folds in the material.
In an embodiment, the method comprises fastening said flooring material to said joists with one or more fasteners.
In an embodiment, the method comprises rolling the material out across the joists.
In an embodiment, the method comprises mounting a roll holder to one end of the floor structure and placing a roll of the material on the roll holder for rolling out across the joists.
In a third aspect, there is provided a floor structure comprising:
In an embodiment, each set of linearly arranged holes allows access to 65 to 90 percent of the length of the joist overlain by the set of holes.
In an embodiment, the spacing of the sets of holes from one another is greater than the spacing of the joists such that, in use, the material between adjacent joists hangs below the top of the joists to define an insulating air gap between the material and the flooring material once the flooring material is installed.
In an embodiment, the material is folded to be formed into a rectangular trough below the flooring material.
In an embodiment, said material is heat reflective or has a heat reflective layer.
In an embodiment, the holes are circular or oval such that the regions of the material around the holes are held taut to lie flat against the joists.
In a fourth aspect, there is provided a tool for installing a material over a plurality regularly spaced joists to insulate a floor structure, the material having a plurality of spaced apart sets of linearly arranged holes extending across the width of the material, the spacing of the sets of holes from one another being greater than the spacing of the joists, the tool comprising:
In an embodiment, the tool is sized so as to be operable by hand.
In an embodiment, at the opening, each side wall terminates in a portion around which the material can be folded so as to form the material into a substantially rectangular trough.
In an embodiment, the portion of each side wall around which the material can be folded extends outwardly of the side wall.
In an embodiment, the tool comprises a triangular cut-out at least one end of the top wall, the apex of the cut-out evenly spaced from each side wall such that it corresponds to the centre of the joist.
In a fifth aspect, there is provided a roll holding apparatus for installing a roll of material over a plurality regularly spaced joists to insulate a floor structure, the roll holding apparatus comprising a pair of leg members, each having a hole therein for receiving a respective end of a spindle around which the material is rolled, each leg member having a foot adapted to be mounted to a beam of the floor structure such that the legs are supported in an upright configuration.
In an embodiment, each foot is of inverted u-shaped cross-section adapted to be placed over the beam.
In an embodiment, each leg member comprises a connection portion adapted to be connected to a connector whereby the leg members can be joined together.
In an embodiment, each connection portion is a sleeve adapted to receive a connector in the form of a rail.
Preferred embodiments of the invention will now be described in relation to the following drawings in which:
In other embodiments, the material may be provided as flat sheets or concertina style sheets.
In the embodiment, the leg members 21B are connected together to prevent them moving apart during installation of the material 1. It will be apparent that in other embodiments the leg members need not be joined together and could be, for example temporarily connected to the double joists 13. In this respect, each leg member 21 has a connecting portion in the form of a sleeve 24 which is adapted to receive rail 25. Each sleeve 24 has holes 26 therein through which some form of connector such as nail or a screw can be connected to the rail 25 to hold the rail in place with the legs at an appropriate separation. It will be appreciated the rail 25 can subsequently be removed by undoing the connector. The rail also makes it easier to move the roll holding apparatus to the next position at which material is to be rolled out.
In an embodiment, a folding tool 30 is used to fold the material over the joists to form rectangular troughs 40 in the material where the material hangs below the top of the joists. Accordingly it will be appreciated that the sets of holes 3 are spaced further apart than the anticipated spacing of the joists. In this respect, in a typical floor structure joist centres are regularly spaced at 450 mm. In other structures though the spacing may vary, for example, it may be a 600 mm spacing between joists centres. The folding tool is used by pushing it down where the material overlies the joists and moving it from one end of the joist to the other along the material so that the holes 3 are aligned with the middle of the top of the joist 12.
Tool 30 has a series of perforations 32 where the top wall 30 meets the side walls 33. These perforations enable the tool to be supplied flat before subsequently being bent into the configuration shown in
The ovals shown in
Accordingly, for a relatively thin material, for example 1 mm or 2 mm to achieve a 90 mm thermal gap between the material 1 and flooring material 90, a 626 mm spacing is required between the centres of the holes. In this example where the joists are 45 mm thick as shown in
While it is preferred that the material is formed of a sheet of heat reflecting material, it will be appreciated that other substrates may be used while obtaining some of the benefits. It is also possible, that more than one substrate can be laid (one on top of the other) to create additional thermal (and reflective) gaps. In another embodiment, the material itself can have plural layers, for example two or more layers such that, for example, one or more layers may be formed of reflective material. Other materials which may provide some or all advantages include multi-layer laminates, air bubble material, expanded foam etc.
In addition to the above, the material may incorporate fold lines, for example, preformed as creases in the material or by small perforations in the surface of the material to aid folding in situ. Alternatively, the positions at which folds are to be made may be indicated by indicia such as printed lines on the material of depth markers. It will be appreciated that the hand tool 30 may eliminate the need for fold depth markers and similarly, physical fold lines may prevent the need for the hand tool.
Indicia can also be used to indicate overlap distance for adjacent sheets of material, for example, line 50 mm and/or 150 mm in from the edges (running parallel with the edge).
Advantages of embodiments of the invention include that:
A person skilled in the art will appreciate that numerous other variations fall within the scope of the invention described herein. For example, while the invention has been described in relation to a wooden structure for supporting flooring material, the invention is equally applicable to situations where the frame is metal.
Further, while the example of fasteners used to attach the substrate to the joists and the flooring to the joists are given above a person skilled in the art will appreciate the number of different fasteners can be used. For example, if a metal floor substrate is used, fasteners in the form of screws would be more appropriate than nails. Further, it may be possible to attach the substrate to the joist using an adhesive rather than staples depending on the embodiment.
Persons skilled in the art will also appreciate that joists and bearers could run in different directions in different areas of the floor structure.
It is to be understood that, if any prior art is referred to herein, such reference does not constitute an admission that the prior art forms a part of the common general knowledge in the art in any country.
In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.
Number | Date | Country | Kind |
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2009905528 | Nov 2009 | AU | national |