Patent Application
20120036808
Metal buildings are popular due to the relatively quick construction and low cost, as well as low maintenance. However, metal components of these buildings have high thermal conductivity, and thus it is difficult to efficiently and effectively control temperatures within such metal buildings. Heating and cooling costs can be relatively high.
Conventional ceiling insulation in metal buildings involves placing a layer of insulating material over the top of the roof purlins, with the roof deck then being attached over the insulation to the purlins. The roof deck squeezes the insulation above each purlin thereby reducing the R-value and increasing energy loss. The insulation is installed from the outside of the building, and involves relatively costly labor which can also be dangerous and difficult in windy or wet conditions.
Applicant's patent 6,330,779 overcame many of the problems associated with conventional insulated ceilings for metal buildings by attaching a substantially rigid insulated sheet to the bottom flange of the purlins and then filling the space between the insulation board and the roofing deck with insulation. However, the insulation board was attached to the purlins using penetrating fasteners, such as self tapping screws. This method of attaching the insulation board to the purlin is time consuming and therefore costly. Also, the metal screws provide thermal conductivity through the metal purlins and metal roof decking, thereby reducing the R-value and increasing energy costs. Applicant's patent 7,107,632 eliminated the screws of its earlier '779 patent, through the use of a clip having support members for receiving the side edges of the ceiling panels, without penetrating screw or pins. This prior art system works fine for rigid ceiling panels, but will not accommodate light weight ceiling fabric, such as plastic or vinyl, which may be used to support blown-in insulation.
Therefore, a primary objective of the present invention is the provision of an improved purlin clip.
Another objective of the present invention is the provision of a purlin clip having an integrally formed pin for piercing a fabric ceiling membrane.
A further objective of the present invention is the provision of an improved purlin clip which can be quickly, easily and securely mounted on a roof purlin for use with blow-in insulation.
Still another objective of the present invention is the provision of an improved purlin clip having a one-piece construction with a pin to penetrate the ceiling membrane.
Yet another objective of the present invention is the provision of an improved purlin clip which is economical to manufacture, and durable and safe in use.
These and other objectives will become apparent from the following description of the invention.
The improved purlin clip of the present invention includes a lower leg and an upper arm defining a channel to receive the horizontal leg of a roof purlin. An integral pin is stamped or formed from the lower leg of the clip, and extends downwardly, such that the clip body and pin have a one-piece construction. The pin includes barbs or teeth and a pointed tip. The pin is adapted to pierce a fabric ceiling membrane, such as vinyl or plastic. A cap is press-fit onto the pin so as to be frictionally retained by the barbs, and so as to support and retain the ceiling membrane on the clip. The cap encloses the pin to minimize or eliminate thermal conductivity or shorting, as well as frost or condensation accumulation on the pin. After the ceiling membrane is secured to a plurality of clips across the ceiling, insulation can be easily blown in between the membrane and the roof deck.
In
Each purlin clip 24 includes a body 26 formed with an upper arm 28, a lower leg 30 and an interconnecting web 32. The arm 28, the leg 30, and the web 32 form a channel 34 for receipt of the lower purlin flange. The arm 28 may have a flared or curved end 36 to facilitate receipt of the clip 24 over the flange 18 of the purlin 12.
Each clip 24 also includes an integrally formed pin 38 which is stamped or punched from the lower leg 30 of the body 26. Thus, the clip 24 has a one-piece construction including both the body 26 and the pin 38. The pin 38 includes a pointed tip 40 and a plurality of teeth or barbs 42 along the length of the pin 38. The pin 38 extends downwardly at 90° from the leg 30 of the clip 24. Because of the integral formation of the pin 38 from the body 26 of the clip 24, the pin is substantially rigid. The pin 38 is adapted to pierce or penetrate the ceiling membrane 22.
After the pin 38 is punched through the membrane 22, a clip cap 44 is press fit onto the pin 38. As seen in
The enlarged head 48 of the cap 44 engages and supports the ceiling membrane 22, and presses the membrane between the cap 44 and the clip 24. The clips 24 and caps 44 allow the membrane 22 to support blown-in insulation without tearing of the membrane 22 adjacent the clip pins 38.
The invention has been shown and described above with the preferred embodiments, and it is understood that many modifications, substitutions, and additions may be made which are within the intended spirit and scope of the invention. From the foregoing, it can be seen that the present invention accomplishes at least all of its stated objectives.
