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. Opposing folded-up edges of the edge-folded ceiling liner sheet are creased on the fold to fit in the encapsulated package. The edge-folded ceiling liner sheet is fan-folded for retention in the encapsulated package. A sheet slot is formed through at least one lengthwise sidewall of the encapsulated package. A removable edge seal strip is applied over the sheet slot. A compressible thermal spacer includes a snap clip and a compressible insulation material. A bottom of the compressible insulation material is bonded to a top of the snap clip. The snap clip is attached to a top flange of a purlin eliminating the need for exposed roof insulation.
Claims
1. An edge-folded ceiling liner sheet for installation over one of a plurality of straps and a support structure located below a bottom of one of primary and secondary structural members of a metal building comprising: a length of a first sheet material having opposed first folded-up edges formed along said length thereof, wherein said length of said first sheet material being fan-folded with said opposed first folded-up edges, said first sheet material is laid on the one of the plurality of straps and the support structure, the one of the plurality of straps and the support structure supports substantially all of a bottom surface area of the first sheet material; and a length of a second sheet material having opposed second folded-up edges, wherein said length of said second sheet material is laid on the one of the plurality of straps and the support structure such that one of said second folded-up edges is adjacent one of said first folded-up edges, the one of the plurality of straps and the support structure supports substantially all of a bottom surface area of the second sheet material, wherein said one of said first folded-up edges and said one of said second folded-up edges are unfolded to overlap each other.
2. The edge-folded ceiling liner sheet of claim 1 wherein: said folded-up edges are creased.
3. An encapsulated package for retaining a ceiling liner sheet for installation over one of a plurality of straps and a support structure located below a bottom of one of primary and secondary structural members of a metal building, comprising: a substantially rectangular package having a sheet slot formed through at least one lengthwise package wall, said sheet slot is parallel with a length of said substantially rectangular package; a length of sheet material having opposed folded-up edges formed along said length thereof, said length of sheet material being fan-folded with said opposed folded-up edges to fit inside said substantially rectangular package, said length of sheet material is retained inside said substantially rectangular package, wherein said opposed folded-up edges are unfolded after removal from said substantially rectangular package; and a removable edge seal strip is applied over said sheet slot.
4. The encapsulated package for retaining a ceiling liner sheet of claim 3 wherein: said folded-up edges are creased.
5. An encapsulated package for retaining a ceiling liner sheet for installation over one of a plurality of straps and a support structure located below a bottom of one of primary and secondary structural members of a metal building, comprising: a substantially rectangular package having a sheet slot formed through at least one lengthwise package wall, said sheet slot is parallel with a length of said substantially rectangular package; a length of sheet material having opposed folded-up edges formed along said length thereof, said length of sheet material being fan-folded with said opposed folded-up edges to fit inside said substantially rectangular package, said length of sheet material is retained inside said substantially rectangular package, wherein said opposed folded-up edges are unfolded after removal from said substantially rectangular package, said substantially rectangular package allows only a portion of said length of sheet material to be exposed to wind during installation of said length of sheet material; and a removable edge seal strip is applied over said sheet slot.
6. The encapsulated package for retaining a ceiling liner sheet of claim 5 wherein: said folded-up edges are creased.
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 snap-on clip of a compressible thermal spacer, compressible insulation not shown, 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 snap-on clip of a compressible thermal spacer, compressible insulation not shown, 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 a rafter snap-on clip of a compressible thermal spacer, compressible insulation not shown, for attachment to a double flange purlin of an insulation support system in accordance with the present invention.
(11) FIG. 11 is an end view of a snap-on clip of a compressible thermal spacer, with compressible insulation shown, attached to a purlin of an insulation support system in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
(12) 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 compressible thermal 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 FIG. 5, 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. An example of a fan-folded ceiling liner sheet 10 cannot be shown in FIGS. 1-4, because of size limitations. However, item 26 in FIG. 11 includes an example of a fan-folded sheet. 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 edge 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.
(13) 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). 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 edge 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 and quickly pull the edge-folded ceiling liner sheet 10 out below the purlins 102 (secondary structural members) on a top side of the plurality of support straps 106 (lattice support) 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.
(14) 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 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 with fasteners penetrating through the edge-folded ceiling liner sheet 10 at those points. The folded-up edges 16 are unfolded and sealed in final position to top flanges of the rafters 108.
(15) It is an option to install insulation from the interior of the building after the roof panels are installed. With reference to FIGS. 8-11, for this option to be used, there is a need for the clip-on compressible thermal spacer 22. The clip-on compressible thermal spacer 22 preferably includes a snap clip 24 or any other suitable attachment device and a compressible insulation material 26. The snap clip 24 preferably includes a upper leg 25 and a lower leg 27. An end of the upper leg 25 is joined to an end of the lower leg 27. The snap clip 24 is fabricated from a material with memory properties. A bottom of the compressible insulation material 26 is preferably adhered to the upper leg 25 of the snap clip 24 with adhesive 30. The snap clip 24 is preferably attached to a top flange of a purlin 102, 104, before the roof panels are applied. With reference to FIG. 10, a double flange purlin 110 is shown with a snap clip 28 attached to two opposing upper flanges 112. The snap clip 28 includes a base member 29, a first end member 31 and a second end member 33. The first end member 31 extends from a first end of the base member 29 and the second end member 33 extends from a second end of the base member 29. The compressible insulation material 26 is adhered to the base member 29 of the snap clip 28 with adhesive 30. The snap clip 24, 28 also provides a conductive thermal break as well as dampens any roof noise or roof rumble from rain and wind actions from the roof panels or building movements. Roof panels will flex during a high wind or fluctuating wind, which can result in very annoying thunder-like noises.
(16) 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 performance or the insulation installation productivity.
(17) 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.
