Patent Application
20220090373
The present invention relates generally structural connectors. More particularly, the present invention relates to a clip for attaching rigid foam insulation to a building's structural members.
The need for properly installed and correctly located insulation is not easily met using current construction practices. Rigid foam insulation board (sometimes referred to as RFB) is, in present common practice, supported by strips of lath (nailers) nailed to the rafters, joists, or beams between which the insulation board is to be installed. Supporting the insulation board while attaching the nailers is difficult, especially if the spacing between the rafters, joists, or beams is insufficient to swing a hammer. Further, precise placement of the nailer is difficult. As such, current practices utilize excess material and require extensive labor in the milling and installing processes to properly install the rigid foam insulation board. This difficulty can in some cases lead to injury because of the difficult maneuvers being performed on ladders and in off-balance positions. Further, precise workmanship of the task is very time consuming and costly. The current products available for providing roof ventilation do not provide a fully vented space. This lack of venting restricts air flow, and promotes moisture entrapment which results in potential ice damming, poor indoor air quality and early deterioration of roof sheathing and roofing.
Therefore, what is needed is a more efficient structure and method of installing rigid foam insulation board.
The subject matter of this application may involve, in some cases, interrelated products, alternative solutions to a particular problem, and/or a plurality of different uses of a single system or article.
In one aspect, a rigid foam insulation board installation clip is provided. The clip comprises a body having a spacer at its distal end, and a connection region at its proximal end. The spacer has a top and a bottom, and has at least a portion of the bottom extending approximately perpendicularly from a front face of the body in a same direction that the spacer extends away from the body. The clip further comprises a plurality of prongs along the body at a distance away from the spacer. These prongs are flexible and can flex as a foam board is urged against them towards the spacer. In some embodiments, the prongs may by approximately cylindrical and may extend from the body. In other embodiments, the prongs may have a square or rectangular cross section. In still further embodiments, the individual prongs may extend from one side of the body to the other widthwise. Accordingly, the prongs may be any structure which can extend away from the body without straying from the scope of this invention. When the foam is properly positioned, the spacer and at least one prong define a cavity between them in which the foam is held. This cavity is defined at a top and bottom by the spacer and at least one prong, respectively, having an open front and sides, and a rear defined by the body.
The detailed description set forth below in connection with the appended drawings is intended as a description of presently preferred embodiments of the invention and does not represent the only forms in which the present invention may be constructed and/or utilized. The description sets forth the functions and the sequence of steps for constructing and operating the invention in connection with the illustrated embodiments.
Generally, the present invention concerns a clip that may be attached to rigid foam board insulation for building insulation, the clip is also configured to be attachable to building structural members. As such, the installation of rigid foam insulation is greatly facilitated. The present clip invention may be used in any condition where rigid foam insulation is being installed. For example, the clip may be used in new construction, existing buildings, renovations, and the like.
The clip consists of a spacer configured to provide an air spacing between a sheathing or flooring and the insulation when installed. A body of the clip may extend downwards away from the spacer. This body is designed to be attached to a building framing or other structural member, such that a rear face of the body may abut the structural member. This allows the foam insulation board to which the clip is attached to be secured in place, and properly spaced from the sheathing. The clip further comprises a series of prongs which extend away from the body of the clip. These prongs extend away from a front face of the body and are flexible. This flexibility allows the foam to be urged upward against the prong towards the spacer. As the foam passes over the prongs, the pressure from the flexed prongs allows the foam to be held in place and resists the foam moving back in the opposite direction.
The installation clip contemplated herein is configured to accept multiple differently sized foam insulations. For example, the most commonly sized insulations have thicknesses of ½ inch, 1 inch, and 1½ inch. The installation clip may be any size capable of connecting to and supporting the foam insulation board. Size may vary depending on application, and it should be understood that the sizing of the clip is in no way limited based on the disclosure herein.
The installation clip contemplated herein may be formed of any material rigid enough to connect to and support the foam insulation board, and resilient enough to be attached to the building structural members. For example, materials of which the installation clip may be made include, but are not limited to, plastics, wood, metals, composite materials, ceramics, combinations thereof, and the like.
The clip may be attached to the building structural members (rafters, joists, beams, etc.) in any manner capable of supporting the insulation. For example, the clip may be mechanically connected to the structural members by fasteners such as nails, staples, screws, tacks, and the like. In other embodiments, adhesives, pressure connections, and the like may be employed. In many cases, gaps are created between the foam insulation boards and the rafters, joists, beams, or the like, to which the insulation boards have been attached. These gaps may be sealed in any manner. In one embodiment, the gaps may be sealed with beads of foam sprayed to bridge these gaps. Framing with irregular centers, or those centers out of parallel may require individual measuring and cutting of the insulation board to fit each location. However, even in such cases, the clips described herein may still be utilized, and the clips may be positioned specifically based on the configuration of the irregular space.
Turning now to
A front face of the body defines a rear of the cavity which is open on its front and sides. In the embodiment shown, the prongs and spacer protrude laterally away from the body to approximately the same distance. As seen in
When thoroughly installed, the spacer ensures that there is a uniform depth of air space between the insulation board and sheathing. Prongs extend from the front face of the body and flex to engage with the foam insulation board as it is urged upward towards the spacer. The flexing and force applied to the foam holds it in place, and also prevents the foam from passing back over the prongs. In some embodiments the prongs may slightly sink into the foam face, thereby “hooking” into it, and further preventing rearward motion of the foam. Positioning of the prongs may vary in some embodiments depending on what size foam insulation is intended to be used. In other embodiments, the clip may be universal and may work for a wide variety of foam thicknesses.
The body of the clip is connected to a building structural member 104 by fasteners (screws, staples, pins, tacks, nails, adhesives, and the like). A foam insulation board 103 is in turn connected to the structural member 104 via the clip. When installed, the foam insulation board 103 will be secured between the spacer 10 and one or more prongs 12, such that it is effectively spaced apart from the upper substrate 101. On an opposite side of the foam, a similar clip is connected to an opposing structural member to hold the opposite end of the foam in place as well. Of course, many clips may be used along the length and/or width of the foam as is needed and depending on the size of the foam insulation board 103 being installed. As shown best in
The body of the clip forms an elongate strip that extends downward from where the spacer secures the insulation board. This extending strip is configured as a connection region to be attached to the building structural members to thereby secure the clip and insulation in place.
As shown, the prongs are positioned along the body at a distance away from the spacer such that at least one of the prongs and the bottom of the spacer define a cavity between them, the cavity having an open front and sides, and a rear defined by the body.
In further embodiments, the present invention may enhance the operation of radiant floor heating. The use of the installation clips described herein will result in uniform distance of air space between the insulation board and the surface beneath which it is suspended. The clips can be used horizontally beneath sub-floor and radiant tubing to attach the insulation boards between floor joists. This uniform distance of air space may provide for consistence spacing of radiant heating components beneath a sub-flooring and may achieve a more uniform floor temperature during the heating season.
Moreover, in some embodiments, the present invention may enhance roof ventilation and insulation. The current standard method for roof ventilation is attached to the roof deck itself and does not allow a fully ventilated cavity, which may introduce ice damming among other problems. This standard method has no structural integrity and will only allow a loose fill insulation be used to fill the remainder of the cavity as opposed to the foam board insulations with clips taught herein which allows for a dense pack insulation to be used. Thus the present invention just allows for a maximized insulating value without the danger of ice damming. Although there are many roof ventilation methods, there are none that provide the ventilation as described in the use of the clips taught herein. Specifically, the use of the installation clips provide ventilation vertically at heels of rafters or roof trusses. Further they allow adequate air sealing and blocking for the remainder of the cavity to be filled with dense pack cellulose or another type of insulation to provide a desired insulation value. Further still, in some embodiments, the clips may be used beneath a roof deck. Further, the vertical installation of the clips and panels when installed at the heels of roof rafters and trusses are important to conforming to the national energy code for insulating over exterior wall plates.
While several variations of the present invention have been illustrated by way of example in preferred or particular embodiments, it is apparent that further embodiments could be developed within the spirit and scope of the present invention, or the inventive concept thereof. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present invention, and are inclusive, but not limited to the following appended claims as set forth. Further, while the clip is described herein as being configured for a foam insulation board, it should be understood that the clip may be used to hold any board or similar elongate element.
| Number | Date | Country | |
|---|---|---|---|
| 63081035 | Sep 2020 | US |
