Seamless sheet insulation around roof structural members

Abstract

A seamless sheet installation system preferably includes a seamless sheet and a plurality of sheet retention devices. The seamless sheet is retained on a tube. A pair of rotating retention devices may be inserted into ends of the roll. Each rolling retention device includes a tube plug and a rotating handle. An end of the seamless sheet is secured to the top eave flange. The seamless sheet is held against a bottom of the eave purlin web with one of the plurality of sheet retention devices. The sheet retention device may have any suitable design. The seamless sheet is rolled out to successive purlins, wrapped over the top flange and anchored to a bottom of the vertical web with one of the plurality of sheet retention devices. The seamless sheet wrapping process is terminated at an opposing eave purlin or a ridge purlin. Insulation is then inserted between adjacent purlins.

Claims

1. A seamless sheet system for attachment to a plurality of purlins of a building, each one of the plurality of purlins includes a top flange, a bottom flange and a vertical portion comprising: a plurality of straps are attached to bottom flanges of the plurality of purlins; said seamless sheet is wrapped over the top flanges of the plurality of purlins and supported by the plurality of straps spanning between the plurality of purlins; a plurality of sheet retention devices having a tubular cross section and an elongated length; said seamless sheet is retained against opposing sides of the vertical portion of the purlin with said plurality of retention devices, said plurality of sheet retention devices retain the seamless sheet through gravity, said plurality of retention devices are not bonded or fastened to the purlin, said plurality of retention devices are bisected by a substantially horizontal line and the retention devices on each side of the vertical portion are axially aligned; and insulation is inserted between adjacent purlins of the plurality of purlins, wherein the plurality of retention devices are capable of being removed when said insulation is installed.

2. The seamless sheet system for attachment to a plurality of purlins of a building of claim 1 wherein: said seamless sheet and said plurality of straps having sufficient strength to withstand the force dropping of a 400 lb. weight from a height of 42 inches.

3. The seamless sheet system for attachment to a plurality of purlins of a building of claim 1, further comprising: said seamless sheet is capable of being retained on a tube.

4. The seamless sheet system for attachment to a plurality of purlins of a building of claim 3 wherein: a rotating retention device is inserted into each end of said tube; and said rotating retention device includes a tube plug and a rotating handle, said rotating handle is rotatably retained relative to said tube plug.

5. The seamless sheet system for attachment to a plurality of purlins of the building of claim 4, further comprising: said seamless sheet having a plurality of transverse strips spaced along a length thereof.

6. The seamless sheet system for attachment to a plurality of purlins of a building of claim 1 wherein: said tubular cross section extends through an entire length of each one of said at least two sheet retention devices.

7. The seamless sheet system for attachment to a plurality of purlins of a building of claim 1 wherein: said at least two sheet retention devices are capable of being withdrawn from the plurality of purlins in a substantially horizontal axis.

8. The seamless sheet system for attachment to a plurality of purlins of a building of claim 1 wherein: said two of said at least two sheet retention devices are located in substantially the same horizontal plane.

9. The seamless sheet system for attachment to a plurality of purlins of a building of claim 1 wherein: said two of said at least two sheet retention devices are located in substantially the same horizontal plane.

10. A seamless sheet system for attachment to a plurality of purlins of a building, each one of the plurality of purlins includes a top flange, a bottom flange and a vertical portion comprising: a plurality of straps are attached to bottom flanges of the plurality of purlins; said seamless sheet is wrapped over the top flanges of the plurality of purlins, said seamless sheet is secured to the top flanges of the plurality of purlins, said seamless sheet is supported by the plurality of straps spanning between the plurality of purlins; a plurality of sheet retention devices having a tubular cross section and an elongated length; said seamless sheet is retained against opposing sides of the vertical portion of the purlin with said plurality of retention devices, said plurality of sheet retention devices retain the seamless sheet through gravity, said plurality of retention devices are not bonded or fastened to the purlin, said plurality of retention devices are bisected by a substantially horizontal line and the retention devices on each side of the vertical portion are axially aligned; and insulation is inserted between adjacent purlins of the plurality of purlins, wherein the plurality of sheet retention devices are capable of being removed when said insulation is installed.

11. The seamless sheet system for attachment to a plurality of purlins of a building of claim 10 wherein: said seamless sheet and said plurality of straps having sufficient strength to withstand the force dropping of a 400 lb. weight from a height of 42 inches.

12. The seamless sheet system for attachment to a plurality of purlins of the building of claim 10, further comprising: said seamless sheet having a plurality of transverse strips spaced along a length thereof.

13. The seamless sheet system for attachment to a plurality of purlins of a building of claim 10 wherein: said tubular cross section extends through an entire length of each one of said at least two sheet retention devices.

14. The seamless sheet system for attachment to a plurality of purlins of a building of claim 10 wherein: said at least two sheet retention devices are capable of being withdrawn from the plurality of purlins in a substantially horizontal axis.

15. A seamless sheet system for attachment to a plurality of purlins of a building, each one of the plurality of purlins includes a top flange, a bottom flange and a vertical portion, comprising: a plurality of straps are attached to bottom surfaces of the bottom flanges of the plurality of purlins; said seamless sheet is wrapped over the plurality of top flanges of the plurality of purlins, said seamless sheet is secured to the top flanges of the plurality of purlins with a plurality of first sheet retention devices, said seamless sheet is supported by the plurality of straps; a plurality of second sheet retention devices having a tubular cross section and an elongated length; said seamless sheet is retained against opposing sides of the vertical portion of the purlin with said plurality of second retention devices, said plurality of second sheet retention devices retain the seamless sheet through gravity, said plurality of second retention devices are not bonded or fastened to the purlin, said plurality of second retention devices are bisected by a substantially horizontal line and the retention devices on each side of the vertical portion are axially aligned; and insulation is inserted between adjacent purlins of the plurality of purlins, wherein the plurality of second sheet retention devices are capable being removed after said insulation is installed.

16. The seamless sheet system for attachment to a plurality of purlins of a building of claim 15 wherein: said plurality of first sheet retention devices are a plurality of retention clips, each one of said plurality of retention clips includes a first leg, a second leg and a spring junction, the spring junction causes an end of said first leg to be biased against an end of said second leg, wherein plurality of retention clips retain said seamless sheet adjacent the vertical portions of the plurality of purlins.

17. The seamless sheet system for attachment to a plurality of purlins of a building of claim 15 wherein: said seamless sheet and said plurality of straps having sufficient strength to withstand the force dropping of a 400 lb. weight from a height of 42 inches.

18. The seamless sheet system for attachment to a plurality of purlins of the building of claim 15, further comprising: said seamless sheet having a plurality of transverse strips spaced along a length thereof.

19. The seamless sheet system for attachment to a plurality of purlins of a building of claim 15 wherein: said tubular cross section extends through an entire length of each one of said at least two sheet retention devices.

20. The seamless sheet system for attachment to a plurality of purlins of a building of claim 15 wherein: said at least two sheet retention devices are capable of being withdrawn from the plurality of purlins in a substantially horizontal axis.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of a metal building.

(2) FIG. 2 is a perspective view of a metal building with a seamless sheet insulation system partially installed thereupon in accordance with the present invention.

(3) FIG. 3 is an end view of a pair of rafters of a metal building with a plurality of purlins attached to the pair of rafters of a seamless sheet insulation system in accordance with the present invention.

(4) FIG. 4 is an enlarged end view of a portion of a rafter and purlins of a metal building with a seamless sheet insulation system installed therein in accordance with the present invention.

(5) FIG. 5 is a perspective view of a retention clip for retaining a seamless sheet of a seamless sheet insulation system in accordance with the present invention.

(6) FIG. 6 is an enlarged end view of a portion of a rafter of a metal building with a seamless sheet insulation system installed therein and utilizing retention clips in accordance with the present invention.

(7) FIG. 7 is a perspective view of a seamless sheet tube with a rotating handle inserted into one end thereof of a seamless sheet insulation system in accordance with the present invention.

(8) FIG. 8 is a side view of a rotating handle of a seamless sheet installation system in accordance with the present invention.

(9) FIG. 9 is an end view of a rotating handle of a seamless sheet installation system in accordance with the present invention.

(10) FIG. 10 is a perspective view of a magnetized sheet retention device of a seamless sheet installation system in accordance with the present invention.

(11) FIG. 11 is a perspective view of a non-magnetized sheet retention device of a seamless sheet installation system in accordance with the present invention.

(12) FIG. 12 is an end view of a release backing tape applied to purlins to retain a seamless sheet of a seamless sheet installation system in accordance with the present invention.

(13) FIG. 13 is a perspective view of a release backing tape with an adhesive cover partially removed by pulling a pull cord of a seamless sheet installation system in accordance with the present invention.

(14) FIG. 14 is a perspective view of a seamless sheet roll with embedded strips of a seamless sheet installation system in accordance with the present invention.

(15) FIG. 15 is an end view of a seamless sheet roll with a plurality of embedded strips attached to a purlin with a plurality of fasteners of a seamless sheet installation system in accordance with the present invention.

(16) FIG. 16 is an enlarged end view of a seamless sheet roll with a plurality of embedded strips of a seamless sheet installation system in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(17) With reference now to the drawings, and particularly to FIG. 1, there is shown a perspective view of a metal building 100. The metal building 100 includes a floor 102, four walls 104, a plurality of columns 106, a plurality of rafters 108 and a roof 110. A bottom of the plurality of columns 106 are anchored to the floor 102 on opposing sides of the metal building 100. The plurality of rafters 108 are attached to a top of the plurality of columns 106. A plurality of roof structural members, such as purlins 112 are attached to a top of the plurality of rafters 108. The purlins 112 are attached directly to a top of a plurality of rafters 108 or the purlins are attached to rafter clips 114, which extend upward from the top of the rafters 108. Roof sheeting 116 is attached to the top of the purlins 112.

(18) With reference to FIGS. 3-4, the roof sheeting 116 is attached to the top of the purlins 112 to form the roof 110. The purlin 112 includes a bottom flange 118, a vertical web 120 and a top flange 122. The bottom flange 118 extends in one direction from a bottom of the vertical web 120 and the top flange 122 extends in an opposite direction from a top of the vertical web 120. An eave purlin 124 is attached to an end of the plurality of rafters 108. The eave purlin 124 includes an eave bottom flange 126, an eave vertical web 128 and an eave top flange 130. The eave bottom flange 126 extends from a bottom of the eave vertical web 128 and the eave top flange 130 extends from a top of the eave vertical web 128 in the same direction. With reference to FIGS. 2,4,6 a plurality of support straps 132 are attached perpendicular to a bottom of the plurality of purlins 112, 124 with a plurality of fasteners 133. A seamless sheet 10 and insulation strip 12 are supported by the plurality of support straps 132.

(19) With reference to FIGS. 4 and 6, seamless sheet installation around roof structural members (seamless sheet installation system) preferably includes the seamless sheet 10 and a plurality of sheet retention devices 38. The seamless sheet 10 is retained on a sheet tube 14. With reference to FIGS. 7-9, a pair of rotating retention devices 16 may be inserted into each end of the sheet tube 14. Each rolling retention device 16 preferably includes a tube plug 18, a rotating handle 20 and bearing 22. The tube plug 18 preferably includes a bearing portion 24, a shoulder 26 and a tube plug portion 28. The bearing portion 24 extends from one end of the shoulder 26 and the tube plug portion 28 extends from an opposite end of the shoulder 26.

(20) The bearing 22 is pressed into a bearing bore 30 formed in an end of the handle 20. A retention washer 32 is preferably secured to an end of the bearing portion 24 with a fastener 34. A plurality of lengthwise projections 36 form an outer perimeter of the tube plug portion 28. The plurality of lengthwise projections 36 contact an inner perimeter of the sheet roll tube 14. The plurality of lengthwise projections 36 are sized to be firmly retained in the inner perimeter of the sheet roll tube 14. A single workman grasps the handle 20 on one of the rotating retention devices 16.

(21) With reference to FIG. 4, an end of the seamless sheet 10 is secured to the top eave purlin flange 130, eave purlin vertical web 128 or eave purlin bottom flange 126 with any suitable means, such as mechanical fasteners 125, adhesives, or double sided tape. The seamless sheet 10 is secured to the purlins 112, 124 to withstand forces of fall protection safety tests. The impact test includes dropping a 400 lb. load from a height of 42 inches to comply with OSHA fall protection safety regulations. With reference to FIGS. 10-11, the seamless sheet 10 is held in a junction between the eave purlin bottom flange 126 and the eave vertical web 128 with one of the plurality of sheet retention devices 38, 40. However, the sheet retention device may have any other suitable design such as shown in traverse strips 156 of a seamless sheet 152 secured to purlins 112, 124 with fasteners 160 in FIGS. 14-16. The sheet retention device 38 preferably includes a plurality of magnetic sections 42 spaced along a length thereof. The sheet retention device 38 preferably has a round shape and a length that extends substantially between two adjacent rafters 108. The plurality of magnetic sections 42 retain the seamless sheet 10 firmly against the purlins 112, 124. The sheet retention device 40 preferably has a rectangular cross section and a length that extends substantially between two adjacent rafters 108.

(22) The seamless sheet 10 is rolled out to the bottom flange 118 of a first purlin 112. The seamless sheet 10 is anchored inside a junction of the bottom flange 118 and a bottom of the vertical web 120 with one of the sheet retention devices 38. The sheet retention device 38 retains the seamless sheet 10 against the purlin 112, 124 by gravity or its own weight; is not secured to the seamless sheet 10 with a bonding agent or fasteners; and may be withdrawn from the seamless sheet after the insulation strip 12 is installed without the use of tools.

(23) The seamless sheet 10 is wrapped over the top flange 122 of the first purlin 112 and anchored against the bottom of the vertical web 120 with one of the sheet retention devices 38. The seamless sheet purlin wrapping process is repeated for successive purlins 112 and is terminated at the eave purlin 124 on the opposite side of the building 100, at a ridge purlin or at any other of a plurality of roof purlins. The end of the seamless sheet 10 is secured to the top eave flange 130, eave purlin vertical web 128 or eave purlin bottom flange 126 with any suitable means, such as mechanical fasteners 125, adhesives or double sided tape. The insulation is then inserted between adjacent purlins 112, 124. The seamless sheet 10 may also be secured to the top flanges of the purlins 112 with a fastener 125. The sheet retention devices 38, 40 may be left in place after the insulation 12 and roof sheet 116 are installed, may be shifted over axially to retain the seamless sheet between another pair of adjacent rafters 108 as the seamless sheet 10 is installed as described above or the retention devices 38,40 may be simply removed for future use in another seamless sheet 10 installation.

(24) With reference to FIGS. 5-6, a retention clip 134 includes a first leg 136, a second leg 138 and a spring junction 140. The spring junction 140 causes an end of the first leg 136 to be biased against an end of the second leg 138. The retention clip 134 is preferably fabricated from a single piece of material, such as spring steel. A plurality of retention clips 134 are used to secure the seamless sheet 10 to a bottom of the top flanges 122 and 130. The plurality of retention clips 134 may be removed, after insertion of the insulation strip 12. However, the plurality of retention clips 134 may be secured to the top flanges 122, 130 with a plurality of fasteners 125.

(25) With reference to FIGS. 12-13, a release backing tape 142 preferably includes a first adhesive cover 144, an adhesive member 146, a second adhesive cover 148 and a pull cord 150. The first and second adhesive covers 144, 146 are attached to opposing sides of the adhesive member 146 to prevent the adhesive member 146 from prematurely sticking to some object. An end of the pull cord 150 is secured to an end of the second adhesive cover 148 with any suitable method. A length of the pull cord 150 is light tacked to the length of the second adhesive cover 148. The first adhesive cover 144 is removed from a first side of the adhesive member 144 and the adhesive member 144 is attached to the purlin 112, 124. The seamless sheet 10 is laid over the purlins 112, 124. The sheet retention devices 38 and 134 may be used to retain the seamless sheet 10 in place, before the insulation 12 is installed between adjacent purlins 112, 124. The second adhesive cover 148 is removed by pulling the pull cord 150 at an opposing end of the seamless sheet 10 adjacent the building rafter 108. The seamless sheet 10 is attached to the vertical webs 120, 128 of the purlin 112,124 by the force applied by an edge of the insulation 12 against the seamless sheet 10 and in turn to the exposed adhesive member 146. The fully applied release backing tape 142 prevents moisture from passing upward past the adhesive member 146 of applied release backing tape 142.

(26) With reference to FIGS. 14-16, a second embodiment of the seamless sheet 152 preferably includes a first sheet layer 154, a plurality of transverse strips 156 and a second sheet layer 158. The plurality of transverse strips 156 are retained between the first and second sheet layers 154, 158, across a width of the seamless sheet 152. The plurality of strips 156 are fabricated from any suitable material. The seamless sheet 152 may be secured to the purlin 112 with a plurality of fasteners 160, tape, clips or any other suitable device.

(27) 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.