VENTED INSULATION UNIT AND SYSTEM

Abstract

A wall insulation system includes a plurality of insulation elements extending along a longitudinal direction. First insulation elements include a first portion proximate a second portion, the first portion having a width greater than the second portion, the first portion having a first face, the first face having grooves formed into the first face. The grooves extend obliquely to the longitudinal direction. A longitudinally extending mounting member is embedded in the first insulating element.

Claims

1. An insulation device comprising: an insulating element extending along a longitudinal direction, comprising a first portion proximate a second portion, the first portion having a width greater than the second portion, the first portion having a first face, the first face having a plurality of grooves formed into the first face, the plurality of grooves extending obliquely to the longitudinal direction; a longitudinally extending mounting member embedded in the insulating element.

2. An insulation device according to claim 1, wherein the plurality of grooves comprises a plurality of parallel grooves.

3. An insulation device according to claim 1, wherein a first surface of each of the grooves extends from a bottom of the groove to the first face at an oblique angle to the first face.

4. An insulation device according to claim 1, wherein a rear surface of the first portion and side surfaces of the second portion are perpendicular.

5. An insulation device according to claim 1, wherein the mounting member has a longitudinal center section and a first section extending laterally from a first edge of the center section and a second section extending laterally from a second edge of the center section.

6. An insulation device according to claim 1, wherein the first section of the mounting member comprises a planar first face having a plurality of transverse channels defining a plurality of first section segments.

7. An insulation device according to claim 1, wherein one of a top and bottom of each insulating element comprises a tongue and the other of the top and bottom comprises a complementary groove.

8. An insulation device according to claim 1, wherein one of a top and bottom of each insulating element comprises a channel extending substantially horizontally when mounted.

9. A wall insulation system comprising: a plurality of insulation units, each of the insulation units comprising: an insulating element extending along a longitudinal direction, comprising a first portion proximate a second portion, the first portion having a width greater than the second portion, the first portion having a first face, the first face having a plurality of grooves formed into the first face, the plurality of grooves extending obliquely to the longitudinal direction; wherein a rear surface of the first portion and side surfaces of the second portion are perpendicular; a longitudinally extending mounting member embedded in the insulating element; a plurality of first insulation panels, wherein an edge of at least one first insulation panel abuts the rear surface of the first portion and one of the side surfaces of the second portion of an adjacent insulation unit.

10. A wall insulation system according to claim 9, further comprising a second insulation panel intermediate two of the insulation units and proximate one of the first insulation panels.

11. A wall insulation system according to claim 9, wherein the plurality of grooves of the insulation element comprises a plurality of parallel grooves.

12. A wall insulation system according to claim 9, wherein a first surface of each of the grooves extends from a bottom of the groove to the first face of the insulation element at an oblique angle to the first face.

13. A wall insulation system according to claim 9, wherein a rear surface of the first portion and side surfaces of the second portion of the insulation element are perpendicular.

14. A wall insulation system according to claim 9, wherein the mounting member has a longitudinal center section and a first section extending laterally from a first edge of the center section and a second section extending laterally from a second edge of the center section.

15. A wall insulation system according to claim 14, wherein the first section of the mounting member comprises a planar first face having a plurality of transverse channels defining a plurality of first section segments.

16. A wall insulation system according to claim 9, wherein one of a top and bottom of each insulating element comprises a tongue and the other of the top and bottom comprises a complementary groove.

17. A wall insulation system according to claim 9, wherein one of a top and bottom of each insulating element comprises a channel extending substantially horizontally when mounted.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Referring now to the drawings, wherein like reference numerals and letters indicate corresponding structures throughout the several views:

[0020] FIG. 1 is a perspective view of an insulation unit according to the principles of the present invention;

[0021] FIG. 2 is a front elevational view of the insulation unit shown in FIG. 1;

[0022] FIG. 3 is a rear elevational view of the insulation unit shown in FIG. 1;

[0023] FIG. 4 is an end view of a first end of the insulation unit shown in FIG. 1;

[0024] FIG. 5 is an end view of a second end of the insulation unit shown in FIG. 1;

[0025] FIG. 6 is a side view of the insulation unit shown in FIG. 1;

[0026] FIG. 7 is a sectional view thereof taken along line 7-7 of FIG. 2;

[0027] FIG. 8 is a perspective view of a stud element embedded in the insulation unit shown in FIG. 1;

[0028] FIG. 9 is a side elevational view of the stud element shown in FIG. 8;

[0029] FIG. 10 is an end view of the stud element shown in FIG. 8;

[0030] FIG. 11 is a top plan view of the stud element shown in FIG. 8;

[0031] FIG. 12 is a bottom plan view of the stud element shown in FIG. 8;

[0032] FIG. 13 is a top perspective view of a wall system including the insulation unit shown in FIG. 1 with portions removed for clarity;

[0033] FIG. 14 is a bottom perspective view of the wall system shown in FIG. 13;

[0034] FIG. 15 is a front elevational view of the wall system shown in FIG. 13;

[0035] FIG. 16 is a rear elevational view of the wall system shown in FIG. 13;

[0036] FIG. 17 is a side sectional view taken along line 17-17 of FIG. 15; and

[0037] FIG. 18 is a bottom sectional taken along line 18-18 of FIG. 15.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0038] Referring now to FIGS. 1-7, there is shown an insulated mounting unit (120) utilized in a wall system (100) shown in FIGS. 13-18, as explained hereinafter. Referring again to FIGS. 1-7, the insulated mounting unit (120) includes an insulating molded foam portion (122) with a stud element (160) embedded within the foam portion (122). The stud (160) extends longitudinally and provides support and mounting surfaces. The insulation unit (120) includes a widened first portion includes a first face (124) having parallel angled channels formed along the first face. The first face (124) also includes mounting marks (154) providing an indication of where fasteners may be attached to extend through the embedded stud element (160). A narrower second portion includes an opposite face (128) with ridges (142) that form gaps to provide capillary action if needed. The first face (124) is wider than the second face (128) and forms shoulder surfaces (132) and (134) that receive conventional planar insulation elements as explained hereinafter. In one embodiment, a widened front portion is 5.5 inches wide, the second portion is 4 inches wide, the insulation has a depth of 2.75 inches and a height of 24 inches. However, sizes may be utilized depending upon the application and requirements. Angled portions (130) extend at each lateral side of the first face and provide a pathway for air and water movement. The insulation units (120) have a generally longitudinal axis that typically extends vertically when the insulation units (120) are mounted. The insulation units (120) may be stacked upon one another and include a tongue (150) at one end and a complementary groove (152) at an opposite end that engage when the insulation units (120) are stacked to align vertically adjacent units (120). Horizontal channels (146) are formed in the top or bottom of insulation unit (120). The channels (146) form laterally extending horizontal chases when the insulation units (120) are stacked for routing wiring and other elements horizontally as may be necessary.

[0039] Chases (148) provide spaces for routing wiring and other elements as necessary vertically. Mounting and cutting guides (158) provide for a center alignment should fasteners need to be extended through to engage the stud elements (160). Notches or slots (156) may also be formed vertically along the side portions (138). The slots and notches (156) generally extend vertically and provide for drainage or surfaces for application of adhesive to mount planar insulation elements, as explained hereinafter.

[0040] The channels (126) generally extend at an oblique angle relative to the vertical axis and provide a plurality of slanted channels extending across the first face (124) of the insulation units (120). The channels (126) have a chamfered lower surface that provides for water to be directed generally outward and prevents water from moving into the wall. In this manner, damage due to moisture is minimized or eliminated.

[0041] Referring now to FIGS. 8-12, the stud element (160) is a light weight molded element that provides internal support for the insulation units (120). The stud (160) is an elongate element that extends generally along the longitudinal axis of the insulation unit (120). The mounting stud (160) has a somewhat “H” shaped cross section with a first planar portion (162) and a second planar portion (168) joined by a center connecting portion (164). The center connecting portion (164) includes connecting ribs (166) that provide openings through which insulation extends to provide greater interaction for the stud (160). The foam of the foam portion extends through the openings and provide an interlocking engagement between the foam portion (122) and the stud (160). The first portion (162) includes internal channels (172) extending laterally transverse to the longitudinal axis. The transverse channels (172) form segments (180) in the first portion (162) and provide greater flexing for the stud (160) and reaction to expansion and contraction of components. The second portion (168) includes ridges (170) extending transverse to the longitudinal axis of the mounting unit (160). The ridges (170) may extend through the second face of the insulation unit (120) and provide for receiving mounting hardware or application of adhesive. It can be appreciated that the stud unit (160) eliminates a thermal connection through the insulation unit (120) and provides for receiving screws, nails or other fasteners, as well as for having adhesive mount to the exposed ridges (170) of the second portion (168) for secure mounting. Adhesive holds the insulation units in tension and eliminate any shrinkage of the insulation units (120). As the insulation units (120) do not shrink when glued in place along the surface (132), gaps do not form and the need for tape, which may fail, to cover gaps is eliminated. The stud (160) may be a molded plastic element with low thermal conductivity. This configuration eliminates a thermal conducting path extending from front to rear through the insulation unit (120) that would undermine the insulating properties of the insulation unit (120).

[0042] Referring now to FIGS. 13-18, a wall system (100) incorporates the insulation units (120) to achieve an insulated wall system. The wall system (100) includes a structural wall (102), which is only partially shown for clarity. The structural wall may be a masonry wall or a wood frame wall or other conventional construction. An insulation layer (104) mounts to the structural wall (102) and includes insulation units (120) spaced apart and used in conjunction with planar insulation elements (108). Supplemental insulation panels (110) may also be utilized between the insulation units (120) to provide even greater R-value if needed. A finishing layer (106) is typically placed on the opposite side of the insulation layer (104) against the front faces (124) of the insulation units (120). It can be appreciated that further insulation layers may be added against the insulation layer (104) and intermediate the structural wall (102) and/or the finishing layer (106). It can also be appreciated that the finishing layer (106) may be paneling, drywall or siding. For some climates and applications a rain shield is added for protection against the elements. The types and number of layers will depend upon the climate and application of the building.

[0043] As shown most clearly in FIG. 18, the insulation units (120) have shoulder surfaces (132) and (134) that form a right angle for receiving a corner of one of the planar insulation elements (108). Moreover, the gaps (142) and the ridges (170) of the mounting elements (160) provide for application of adhesive for securely mounting the various elements to the insulation units (120). It can also be appreciated that the finishing layer (106) may be mounted to the insulation units (120) with fasteners extending through to engage the studs (160), but do not extend entirely through the depth of the wall system (100).

[0044] The slanted channels (126), the angled portions (130) forming channels proximate the first face as well as the ridges (142) and the notches (156) provide pathways that allow for capillary breaks, drainage and ventilation to extend vertically within the wall system. Moreover, the channels (126) provide angled cross ventilation in addition to air being moved across and upward through the wall system (100). The same angled channels (126), along with the spaces formed by the angled portions (130) and the ridges (142) and notches (156) provide for moisture to flow downward under the force of gravity within the wall system. The lowermost insulation units (120) and corresponding insulation panels (108) or (110) generally are installed with a gap at the bottom of the wall and the uppermost insulation units (120) and corresponding insulation panels (108) or (110) generally are installed with a gap at the top of the wall system (100). The gaps promote faster drying increase air movement. As air naturally rises as it warms, the wall system (100) pulls fresh air at the bottom. For outer walls, this air naturally heats up with the sun warming and creates a rising warm air stream that promotes quick drying. The air will be vented to the outside at the top of the wall system (100). In this manner, the wall system (100) is able to provide internal ventilation and to eliminate internal moisture buildup within the wall system (100). It can also be appreciated that the materials used in the insulation layer (104) are water and mold resistant and will not rot. It can also be appreciated that the insulation system (100) achieves a superior insulating properties and eliminates thermally conductive pathways extending through the insulation layer (104).

[0045] It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.