Abstract
An insulation support system preferably includes an edge-folded ceiling liner sheet, an encapsulated package and a plurality of compressible thermal spacers. The edge-folded ceiling liner sheet includes opposed folded-up edges. The folded-up edges have sufficient length to clear pinch points along structural beams. The edge-folded ceiling liner sheet is fan-folded for retention in the encapsulated package. A pressure absorbing expansion spacer prevents roof or wall panel rumble noises and may be applied directly to roof or wall structural members, or may include a snap clip bonded to a pressure absorbing expansion spacer material. A bottom of the pressure absorbing expansion material is bonded to a top of the snap clip. The snap clip is attached to flanges of purlins or girts eliminating the need for stand-off roof panel clips, rigid thermal blocks and severe compression of an extra layer of blanket fiber glass insulation.
Claims
1. A method of utilizing a pressure absorbing expansion spacer for preventing undulation of at least one sheeting panel relative to a roof or wall structural member, comprising the steps of: installing said pressure absorbing expansion spacer between the roof or wall structural member and the at least one sheeting panel, said pressure absorbing expansion spacer being composed of a resilient material having memory properties, the roof or wall structural member is permanently attached to a rafter; preloading said pressure absorbing expansion spacer between the at least one sheeting panel and the roof or wall structural member such that a height of said pressure absorbing spacer is decreased; and attaching said pressure absorbing expansion spacer to a flange of the roof or wall structural member via an attachment means; wherein said pressure absorbing expansion spacer prevents the at least one sheeting panel from undulating relative to the roof or wall structural member, said pressure absorbing expansion spacer compresses and expands to maintain contact with at least one sheeting panel, which prevents undulation when said pressure absorbing expansion spacer makes contact with the at least one sheeting panel, wherein said pressure absorbing expansion spacer prevents noise caused by the undulation of the at least one sheeting panel relative to the roof or wall structural member.
2. The method of claim 1 wherein: the attachment means is a snap clip, said pressure absorbing expansion spacer is attached to said snap clip with one of a bonding substance, double sided tape or adhesive.
3. The method of claim 1 wherein: the roof or wall structural member is one of a purlin, girt and joist style purlin.
4. The method of claim 1 wherein: the roof or wall structural member is a joist style purlin with two opposing top flange legs.
5. The method of claim 1 wherein: thermal insulation is installed adjacent said pressure absorbing expansion spacer to add thermal performance to the roof or wall structural member and the at least one sheeting panel.
6. A method of utilizing a pressure absorbing expansion spacer for preventing undulation of at least one sheeting panel relative to a roof or wall structural member, comprising the steps of: installing said pressure absorbing expansion spacer between the roof or wall structural member and the at least one sheeting panel, said pressure absorbing expansion spacer being composed of a resilient material having memory properties, the roof or wall structural member is permanently attached to a rafter; preloading said pressure absorbing expansion spacer between the at least one sheeting panel and the roof or wall structural member such that a height of said pressure absorbing spacer is decreased; and attaching said pressure absorbing expansion spacer to a flange of the roof or wall structural member via an attachment means; wherein said pressure absorbing expansion spacer prevents the at least one sheeting panel from undulating relative to the roof or wall structural member, wherein said pressure absorbing expansion spacer provides a resistive force against movement of the at least one sheeting panel, wherein said pressure absorbing expansion spacer prevents noise caused by the undulation of the at least one sheeting panel relative to the roof or wall structural member.
7. The method of claim 6 wherein: the attachment means is a snap clip, said pressure absorbing expansion spacer is attached to said snap clip with one of a bonding substance, double sided tape or adhesive.
8. The method of claim 6 wherein: the roof or wall structural member is one of a purlin, girt and joist style purlin.
9. The method of claim 6 wherein: the roof or wall structural member is a joist style purlin with two opposing top flange legs.
10. The method of claim 6 wherein: thermal insulation is installed adjacent said pressure absorbing expansion spacer to add thermal performance to the roof or wall structural member and the at least one sheeting panel.
11. A method of utilizing a pressure absorbing expansion spacer for preventing undulation of at least one sheeting panel relative to a roof or wall structural member, comprising the steps of: installing said pressure absorbing expansion spacer between the roof or wall structural member and the at least one sheeting panel, said pressure absorbing expansion spacer being composed of a resilient material having memory properties, the roof or wall structural member is permanently attached to a rafter; preloading said pressure absorbing expansion spacer between the at least one sheeting panel and the roof or wall structural member such that a height of said pressure absorbing spacer is decreased; attaching said pressure absorbing expansion spacer to a flange of the roof or wall structural member via an attachment means; wherein said pressure absorbing expansion spacer prevents the at least one sheeting panel from undulating relative to the roof or wall structural member, said pressure absorbing expansion spacer resists movement of the at least one sheeting panel, wherein said pressure absorbing expansion spacer prevents noise caused by the undulation of the at least one sheeting panel relative to the roof or wall structural member.
12. The method of claim 11 wherein: the attachment means is a snap clip, said pressure absorbing expansion spacer is attached to said snap clip with one of a bonding substance, double sided tape or adhesive.
13. The method of claim 11 wherein: the roof or wall structural member is one of a purlin, girt and joist style purlin.
14. The method of claim 11 wherein: the roof or wall structural member is a joist style purlin with two opposing top flange legs.
15. The method of claim 11 wherein: thermal insulation is installed adjacent said pressure absorbing expansion spacer to add thermal performance to the roof or wall structural member and the at least one sheeting panel.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) FIG. 1 is a perspective view of an encapsulated package of an insulation support system in accordance with the present invention.
(2) FIG. 2 is an edge-folded ceiling liner sheet removed from an encapsulated package of an insulation support system in accordance with the present invention.
(3) FIG. 3 is a perspective view of an encapsulated package with opposing edges of an edge-folded ceiling liner sheet extending from opposing ends of the encapsulated package of an insulation support system in accordance with the present invention.
(4) FIG. 4 is an end view an encapsulated package located between two adjacent purlins with an edge-folded ceiling liner sheet extending from opposing lengthwise sides of the encapsulated package of an insulation support system in accordance with the present invention.
(5) FIG. 5 is a perspective view an encapsulated package located between two adjacent purlins with an edge-folded ceiling liner sheet extending from opposing longwise sides of the encapsulated package of an insulation support system and a second edge-folded ceiling sheet installed, adjacent to encapsulated package in accordance with the present invention.
(6) FIG. 6 is a perspective view a top of a metal building with an encapsulated package located between two adjacent purlins at a ridge thereof of an insulation support system in accordance with the present invention.
(7) FIG. 7 is a perspective view a top of a metal building with an encapsulated package located between an eave purlin and a regular purlin of an insulation support system in accordance with the present invention.
(8) FIG. 8 is an end view of a pressure absorbing expansion spacer for attachment to a purlin of an insulation support system in accordance with the present invention.
(9) FIG. 9 is an end view of a pressure absorbing expansion spacer for attachment to an eave purlin of an insulation support system in accordance with the present invention.
(10) FIG. 10 is an end view of pressure absorbing expansion spacer for attachment to a joist style purlin of an insulation support system in accordance with the present invention.
(11) FIG. 11 is an end view of a pressure absorbing expansion spacer attached to a purlin of an insulation support system with a snap clip in accordance with the present invention.
(12) FIG. 11a is an end view of a pressure absorbing expansion spacer attached to a purlin of an insulation support system with adhesive, cement or double sided tape in accordance with the present invention.
(13) FIG. 11b is an end view of a pressure absorbing expansion spacer attached to a roof sheet and in contact with a newly added roof sheet in accordance with the present invention.
(14) FIG. 12 is an end view of a pressure absorbing expansion spacer attached to an angled roof support and in contact with a sloped roof in accordance with the present invention.
(15) FIG. 12a is an end view of a pressure absorbing expansion spacer attached to a sloped roof and in contact with a newly added sloped roof sheet in accordance with the present invention.
(16) FIG. 13 is an end view of a pressure absorbing expansion spacer attached to a wall girt and contacting an outer wall sheet in accordance with the present invention.
(17) FIG. 13a is an end view of a pressure absorbing expansion spacer attached to an outer wall sheet and in contact with a newly added side wall sheet in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
(18) With reference now to the drawings, and particularly to FIG. 1, there is shown a perspective view of an encapsulated package of an insulation support system. With reference to FIGS. 1-3, 5 and 11, the insulation support system preferably includes an edge-folded ceiling liner sheet 10, an encapsulated package 12 and a clip-on pressure absorbing expansion spacer 22. The encapsulated package 12 is also protected from the weather. The edge-folded ceiling liner sheet 10 includes opposed folded-up edges 16. With reference to FIGS. 3-4, the folded-up edges 16 have sufficient length to clear the frequent pinch points along both adjacent primary structural beams. The opposing folded-up edges 16 of the edge-folded ceiling liner sheet 10 are creased on the fold to fit neatly into the encapsulated package 12. The encapsulated package 12 has a substantially rectangular shape. The edge-folded ceiling liner sheet 10 is fan-folded in a dimension sufficient to be retained in the encapsulated package 12. With reference to FIGS. 1 and 3, a sheet slot 18 is formed through at least one lengthwise sidewall of the encapsulated package 12. A removable sheet slot seal strip 20 is applied over the sheet slot 18, until removal of the edge-folded ceiling liner sheet 10 from the encapsulated package 12.
(19) With reference to FIGS. 3-7, the encapsulated package 12 is placed between purlins 102 or eave purlins 104 of a building support structure 100 on top of a plurality of support straps 106 (lattice support, many other support strap patterns not shown). The purlins 102, 104 are supported by rafters 108. When workmen are ready to pull out the edge-folded ceiling liner sheet 10 in a desired building bay, between two rafters 108, the removable sheet slot strip 20 is pulled off the encapsulated package 12 and two crew men take only the opposing top corners of the edge-folded ceiling liner sheet 10 out of the encapsulated package 12 through the sheet slot and quickly pull the edge-folded ceiling liner sheet 10 out of the encapsulated package below the purlins 102 (secondary structural members) on a top side of the plurality of support straps 106 (lattice support) as the edge folded liner sheet unfolds one fan-fold or pleat at a time inside of the encapsulated package without worrying about the edge-folded ceiling liner sheet 10 being subject to a gust of wind, or folded-up edges 16 being caught at pinch points. An unused portion of the edge-folded ceiling liner sheet 10 remains protected in the encapsulated package 12. The fan-folded ceiling liner sheet 10 remains protected inside the encapsulated package 12 out of any wind and potential weather exposures. A board or other weight can be placed on the top of the encapsulated package 12 to provide a desired degree of resistance to the edge-folded ceiling liner sheet 10 within being pulled out of the encapsulated package 12.
(20) With reference to FIGS. 4-5, another option is to clamp two opposing top end corners of the edge folded ceiling liner sheet 10 at the beginning end to the eave purlin 104 (secondary structural member) with C-clamp vise grips 105 and then pull the encapsulated package 12 on the plurality of support straps 106 (lattice support) as the edge-folded ceiling liner sheet 10 dispenses out of a trailing side sheet slot of the encapsulated package 12. A length of the encapsulated package 12 is less than a distance between the two adjacent rafters 108 (primary structural members) to avoid any interference with pulling the package or sheet along the plurality of support straps 106 (lattice support). With either option, once the edge-folded ceiling liner sheet 10 is pulled into position and clamped securely in position, bottom side fasteners are installed to attach the plurality of support straps 106 to bottoms of the purlins 102, at all intersection points, with fasteners penetrating through the steel strap and the edge-folded ceiling liner sheet 10 at each of those intersection points where a strap crosses under a purlin. The folded-up edges 16 are unfolded, trimmed as needed and sealed in final position at the top flanges of the rafters 108.
(21) It is an option to install insulation from the interior of the building after roof panels 107 are installed. With reference to FIGS. 8-11 for this option to be used, there is a need for the application of a pressure absorbing expansion spacer 22 in the roofing process to prevent roof rumble noises. The pressure absorbing expansion spacer 22 preferably includes a snap clip 24 or any other suitable attachment means and a pressure absorbing expansion spacer material 26. The snap clip 24 preferably includes an upper leg 28, a base portion 30 and a lower leg 32. One end of the upper leg 28 extends outward from a top of the base portion 30 and one end of the lower leg 32 extends outward from a bottom of the base portion 30. A downward lip 34 extends downward from an opposing end of the upper leg 28 to engage a horizontal flange 103 of a purlin 102 or a horizontal flange 109 of a purlin 104 or the like. The lower leg 32 preferably includes a clamping portion 36 and an angled insertion end 38. The angled insertion end 38 extends from the clamping portion 36. The angled insertion end 38 facilitates quick insertion of the horizontal flange 103, 109 into the snap clip 24. The snap clip 24 is fabricated from a material with memory properties. Memory properties means that, after the snap clip 24 is opened to insert a horizontal flange 103, 109, it will return to its original shape. A bottom of the pressure absorbing expansion spacer 26 is pre-attached to the upper leg 28 of the snap clip 24 with adhesive, cement, double sided tape or the like 40. The snap clip 24 is preferably attached to the horizontal flange 103 of the purlin 102, the horizontal flange 109 of the purlin 104 or a linear structural member, before the roof panels 107 are applied. A ceiling sheet 132 supports insulation 130.
(22) With reference to FIG. 10, a joist style purlin 110 is shown with a snap clip 31 attached to two opposing horizontal flanges 112. The joist style purlin snap clip 31 includes a base member 42, a first end member 44 and a second end member 46. A clip-on pressure absorbing expansion spacer 29 preferably includes a snap clip 31 or any other suitable attachment means and the pressure absorbing expansion spacer material 26. The first end member 44 extends from a first end of the base member 42 and the second end member 44 extends from a second end of the base member 42. The joist style purlin snap clip 31 is fabricated from a material with memory properties. The first and second end members 44, 46 preferably include a curved contour, but other shapes may also be used. The pressure absorbing expansion spacer material 26 is attached to the base member 42 of the joist style purlin snap clip 31 with the adhesive, cement, double sided tape or the like 40. The pressure absorbing expansion spacers 22, 29 provide dampening of roof noise or roof rumble from rain and wind actions from the roof panels or from building movements.
(23) With reference to FIG. 11a, the pressure absorbing expansion spacer 26 may also be attached directly to the horizontal flange 103 with a bonding substance, double sided tape 48, adhesive or the, like. With reference to FIG. 11b, the pressure absorbing expansion spacer material 26 may also be attached directly to an existing roof sheet 128 or an adaptive fastening structure (not shown) with a bonding substance, double sided tape 48 or like. A replacement roof sheet 111 will flex during a high wind or undulating wind, which can result in very annoying thunder-like noises, without installation of the pressure absorbing expansion spacer 26. An adaptive structural bracket 124 may be used to attach the newly added roof sheet 111 to the existing roof sheet 128. A fastener 126 is used to attach the structural bracket 124 to the horizontal flange 103 of the roof purlin 102. Insulation 130 is placed above the existing roof sheet 128. An existing ceiling sheet 132 is used to support the existing insulation 130, below the existing roof sheet 128.
(24) With reference to FIG. 12, the pressure absorbing expansion spacer 26 is attached to the horizontal flange 103 of the roof purlin 102 with a bonding substance, double sided tape 48 or like. The pressure absorbing expansion spacer 26 is positioned, such that it makes contact with a sloped roof sheet 116. With reference to FIG. 12a, the pressure absorbing expansion spacer 26 is attached to an existing sloped roof sheet 128 with a bonding substance, double sided tape 48 or like. The pressure absorbing expansion spacer 26 is positioned, such that it makes contact with a newly added sloped roof sheet 117. A structural bracket 124 is used to attach a newly added roof sheet 117 to the existing roof sheet 128. A fastener 126 is used to attach the structural bracket 124 to the horizontal flange 103 of the roof purlin 102. Insulation is placed between the existing roof sheet 128 and the replacement roof sheet 117.
(25) With reference to FIG. 13, the pressure absorbing expansion spacer material 26 is attached to the vertical flange 103 of a horizontal wall purlin (girt) with a bonding substance, double sided tape 48 or like. The pressure absorbing expansion spacer material 26 is positioned, such that it makes contact with a new outside wall sheet 120. With reference to FIG. 13a, the pressure absorbing expansion spacer material 26 is attached to the existing wall sheet 120 with a bonding substance, double sided tape 48 or like. The pressure absorbing expansion spacer 26 is positioned, such that it makes contact with a new outside wall sheet 122. The structural bracket 124 is used to attach the new outside wall sheet 122 to the existing side wall sheet 120. The fastener 126 is used to attach the structural bracket 124 to the vertical flange 103 of the wall purlin (girt). New insulation 130 is placed between the existing wall sheet 120 and the new outside wall sheet 122.
(26) The installation of these improvements to metal buildings allow for the rapid enclosure of the building with the least adverse effects of wind and other weather variables as the insulation can be substantially installed from the interior of the building by installing insulation on the edge folded ceiling liner sheet 10 over the rafters 108 to fill all cavities under the roof between two adjacent rafters 108 without adverse effects of weather on the qualities of optimal thermal performance or the insulation installation productivity. The installation of the pressure absorbing expansion spacer material 26 under building new roof sheets and wall sheet will dampen roof or wall noise, allow the new insulation 130 to be installed in the new or existing building roofs and walls without the need to severely compress thermal insulation and allow the thermal insulation to be installed at full thickness between the pressure absorbing expansion spacers to dampen roof and wall sheeting noises, achieve significant increased performance and reduce delays and costs.
(27) It is preferable that in FIGS. 11, 11a, 11b, 12, 12a, 13 and 13a that the expansion spacer 26, be preloaded, such that a height of the expansion spacer 26 is decreased. The expansion spacer 26 is preloaded between the roof 107,116,128 or the wall 120, and a support structure 102,103, the second roof 111, 117 or the second wall 122. It is also preferable that the expansion spacer 26 have memory, such that it returns to its original shape, after removal from a compressed state. The expansion spacer provides resistive force against the movement of the support structure 102,103, the second roof 111, 117 or second wall 122.
(28) While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention.
