INSULATIVE BUILDING PANELS

Abstract

A panel is disclosed for use in insulating an edifice that includes a first pane, a second pane in engagement with the first pane so as to define a channel there between configured and dimensioned for drainage and air flow, a clip in engagement with the first and second panes, and an insulator including an upper portion that is positioned within the clip. A system for use in insulating an edifice includes identical panels, wherein the insulator of one panel is positionable within the clip of another panel to connect the panels together. A panel clip for use in insulating an edifice includes a first arm defining an outer surface with a plurality of connectors, a saddle extending from the first arm, and a second arm connected to the saddle opposite the first arm such that the clip is generally H-shaped in configuration.

Claims

1. A starter track for use in insulating an edifice, the starter track comprising: an outer arm; an intermediate arm; an inner arm; and a saddle extending from the outer arm and connected to the intermediate arm and to the inner arm such that the outer arm, the intermediate arm, and the saddle define an outer chamber, and such that the intermediate arm, the inner arm, and the saddle define an inner chamber, wherein the starter track is configured for use in receiving insulative panels in the inner and outer chambers and is configured for drainage of moisture from the inner and outer chambers.

2. The starter track of claim 1, wherein the outer arm includes a series of weep holes spaced along a base of the outer arm adjacent the saddle, and the intermediate arm includes a series of weep holes spaced along a base of the intermediate arm adjacent the saddle.

3. The starter track of claim 2, further comprising a graded drainage panel extending from the starter track adjacent the base of the outer arm.

4. The starter track of claim 1, wherein the insulative panels comprise an insulator, and first and second panes connected to each other and defining a channel therebetween configured for drainage of moisture; wherein the inner chamber is configured and dimensioned to receive a lower portion of the insulator and the outer chamber is configured and dimensioned to receive a lower portion of the connected first and second panes.

5. The starter track of claim 4, wherein the saddle includes dimples configured to support the insulator above a surface of the saddle to accommodate drainage of moisture from the insulator.

6. The starter track of claim 1, wherein the insulative panels comprise a series of interconnected panels in vertical relation, wherein a lowermost panel of the series of interconnected panels is engageable with the starter track.

7. The starter track of claim 1, wherein the inner arm and the intermediate arm each define a length, the length of the inner arm being greater than the length of the intermediate arm so as to define an extension configured to receive a plurality of fasteners to facilitate securing the starter track to a foundation wall of the edifice.

8. The starter track of claim 1, wherein the outer arm, the intermediate arm, the inner arm, and the saddle are formed of a water-impervious material.

9. The starter track of claim 1, wherein the outer arm, the intermediate arm, the inner arm, and the saddle are formed of a material that limits conduction of heat.

10. A system for use in insulating an edifice, the system comprising: a starter track including an outer arm, an inner arm, and a saddle; wherein the saddle extends from the outer arm and is connected to the inner arm such that the outer arm, the inner arm, and the saddle define a chamber above the saddle; wherein the outer arm includes a series of weep holes spaced along a base of the outer arm adjacent the saddle; and insulative panels engageable with the starter track, the insulative panels configured and dimensioned for drainage of moisture; wherein a lower portion of the insulative panels is positioned within the channel.

11. The system of claim 10, wherein the chamber comprises an outer chamber and an inner chamber and the starter track further comprises an intermediate arm; wherein the saddle extends from the outer arm and is connected to the intermediate arm such that the outer arm, the intermediate arm, and the saddle define the outer chamber above the saddle; and wherein the intermediate arm, the inner arm, and the saddle define the inner chamber above the saddle.

12. The system of claim 11, wherein the intermediate arm includes a series of weep holes spaced along a base of the intermediate arm adjacent the saddle.

13. The system of claim 11, wherein the inner arm and the intermediate arm each define a length, the length of the inner arm being greater than the length of the intermediate arm so as to define an extension configured to receive a plurality of fasteners to facilitate securing the starter track to a foundation wall of the edifice.

14. The system of claim 11, wherein the insulative panels comprise inner and outer panes connected to each other and defining a channel therebetween, and an insulator; wherein a lower portion of the connected inner and outer panes is positioned within the outer channel, and a lower portion of the insulator is positioned within the inner channel.

15. The system of claim 14, wherein the saddle includes dimples configured to support the insulator above a surface of the saddle to accommodate drainage of moisture from the insulator.

16. The system of claim 10, further comprising a graded drainage panel extending from the starter track adjacent the base of the outer arm.

17. The system of claim 10, wherein the insulative panels comprise a series of interconnected panels in vertical relation, wherein a lowermost panel of the series of interconnected panels is engageable with the starter track.

18. A panel clip for use in insulating an edifice, the panel clip comprising: a first arm defining an outer surface including a plurality of connectors; a saddle extending from the first arm; and a second are connected to the saddle opposite the first arm such that the panel clip is generally H-shaped in configuration.

19. The panel dip of claim 18, wherein the first arm and second arm each define a length, the length of the first arm being greater than the length of the second arm so as to define an extension configured to receive a plurality of fasteners.

20. The panel clip of claim 18, wherein the panel dip defines a length within the range of 4-10.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0032] The present disclosure can be better understood by referring to the following figures. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the disclosure. In the figures, reference numerals designate corresponding parts throughout the different views.

[0033] FIG. 1 is a side, cross-sectional view of an insulative panel according to the principles of the present disclosure that includes inner and outer panes, an insulator, and a clip, in accordance with an embodiment.

[0034] FIG. 2 is a side, cross-sectional view of the insulative panel with parts separated, in accordance with the embodiment of FIG. 1.

[0035] FIG. 3 is a side, cross-sectional view of the clip of the embodiment of FIGS. 1 and 2.

[0036] FIG. 4 is a perspective, end view of the clip of the embodiment of FIGS. 1 and 2.

[0037] FIG. 5 is a front, elevational view of a series of insulative panels secured together to form an insulative system configured as a wall, in accordance with an embodiment.

[0038] FIG. 6 is a side, cross-sectional view illustrating the plurality of insulative panels of the embodiment of FIG. 5, prior to connection.

[0039] FIG. 7 is a side, cross-sectional view illustrating the plurality of insulative panels of the embodiment of FIG. 5, following connection.

[0040] FIG. 8 is a side, cross-sectional view of a starter track in accordance with an embodiment.

[0041] FIG. 9 is a perspective, end view of the starter track of the embodiment of FIG. 8.

[0042] FIG. 10 is a side, cross-sectional view illustrating a plurality of connected insulative panels, including a lowermost insulative panel secured to the starter track of the embodiment of FIG. 8.

DETAILED DESCRIPTION

[0043] The present disclosure is here described in detail with reference to embodiments illustrated in the drawings, which form a part here. Other embodiments may be used and/or other changes may be made without departing from the spirit or scope of the present disclosure. The illustrative embodiments described in the detailed description are not meant to be limiting of the subject matter presented here.

[0044] Reference will now be made to the exemplary embodiments illustrated in the drawings, and specific language will be used here to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Alterations and further modifications of the inventive features illustrated here, and additional applications of the principles of the inventions as illustrated here, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention. Throughout the present disclosure, the terms front, rear, upper, lower, inner, outer, etc. are used in a relative capacity, and should be interpreted in accordance with the perspective shown in the corresponding figure(s).

[0045] This specification relates generally to insulative technologies and structures, and more particularly, to improved insulation panels for use in insulating an edifice in residential and/or commercial applications, e.g., a home, an office building, etc., and provide a number of benefits over known technologies. For example, the present disclosure describes insulative panels, and corresponding methods of use and installation, that can be easier to install than conventional insulation and more resistant to thermal energy losses.

[0046] With reference to FIGS. 1-4, an insulative panel 1000 is disclosed that includes respective inner and outer panes 102, 104, an insulator 200, and a clip 300.

[0047] The panes 102, 104 may be formed from any suitable insulative material, i.e., any material that limits heat conduction. For example, in one embodiment, the panes 102, 104 may be formed from polyethylene terephthalate (PET), e.g., to reduce material costs, and incorporate a green material.

[0048] The panes 102, 104 include respective inner surfaces 106, 108 (FIG. 2) having a plurality of connectors 110, 112 that are configured and dimensioned for mating engagement. For example, the connectors 110, 112 may be configured and dimensioned for mechanical engagement, e.g., in a pressure-fit or snap-fit manner, or may be fused together, e.g., through the use of an adhesive, such as contact cement, or through the application of heat. Upon mating engagement of the connectors 110, 112, an interior channel 114 (FIG. 1) is created that is configured and dimensioned for fluid communication, drainage, and/or air flow. The interior channel 114 can accommodate drainage of liquid water intrusion, e.g., due to rain, snow melt, or flooding; and that the channel facilitates or permits air flow, e.g., to permit drying of the insulative panel 1000 in the event of exposure to moisture. The interior channel 114 (also referred to as a channel) provides a clear passage for any moisture that may condense or otherwise form within the insulative panels, and as described below, an insulative system including an assembly of panels 1000 may include flashing with weep holes for drainage of this moisture. The interior channel can include the air space between the inner surfaces 106, 108. In the event panels 102, 104 are formed of a porous material, the pore structures of these panels may also provide drainage and facilitate drying.

[0049] In the embodiment seen in FIGS. 1 and 2, the connectors 110, 112 are configured as circular projections, e.g., dimples, that are in diameter. The configuration and dimensions of the connectors 110, 112 may be varied in alternate embodiments, however, without departing from the scope of the present disclosure. For example, the connectors 110, 112 maybe square, triangular, elliptical, etc., and may define transverse cross-sectional dimensions either larger or smaller than . Additionally, although illustrated with connectors identical in configuration and dimensions, the present disclosure contemplates the incorporation of non-identical connectors 110, 112.

[0050] In one embodiment of the disclosure, the panes 102, 104 each define a thickness of 3/16. The thickness of the panes 102, 104, may be altered or varied in alternate embodiments of the present disclosure to suit a particular need or construction.

[0051] The outer pane 104 defines a length L1 (FIG. 2), and the inner pane 102 defines a length L2. In the illustrated embodiment, the panes 102, 104 are dimensioned such that the length L1 exceeds the length L2. In alternate embodiments of the disclosure, however, the panes 102, 104 may be dimensioned such that L1 and L2 are equal, or such that L2 exceeds L1.

[0052] With continued reference to FIGS. 1-4, the insulator 200 is positioned adjacent to the inner pane 102, and increases the insulative properties of the panel 1000. In one embodiment, the insulator 200 may include a high-density foam board, e.g., polyisocyanurate rigid insulation. Alternatively, the insulator 200 may include any material that creates a suitable thermally insulative barrier, either exclusively, or in combination with other materials. In various embodiments, it is also envisioned that the insulator 200 may include water resistant properties, e.g., a coating, film, or the like, and/or that the insulator 200 may be formed from a plurality of layers of material laminated or otherwise secured together.

[0053] The insulator 200 defines a thickness T (FIG. 2) that can be varied to create any desired insulative value. For example, in the embodiment of the disclosure illustrated in FIG. 2, the thickness T is approximately 3. A thickness T in the range of 1-12 is also contemplated herein.

[0054] With reference now to FIGS. 3 and 4 in particular, the clip 300 will be discussed. The clip 300 is configured, dimensioned, and adapted to connect the panes 102, 104 (FIGS. 1, 2) and the insulator 200, and may be formed from any material suitable for this intended purpose. For example, the clip 300 may be formed from the same material as the panes 102, 104, e.g., PET, or alternatively, the clip 300 may be formed from a different material, e.g., acrylonitrile butadiene styrene (ABS). To maximize efficiency of the insulative panel 1000 (FIGS. 1 and 2), it is envisioned that the clip 300 may also be formed from a material that limits heat conduction.

[0055] The clip 300 includes an outer arm 302, an inner arm 304, and a saddle 306, and is generally H-shaped in configuration. The outer arm 302 defines a height H1, and the inner arm 304 defines a height H2. In the embodiment illustrated in FIGS. 3 and 4, the arms 302, 304 are dimensioned such that the height H2 exceeds the height H1 so as to define an extension 308 that is configured and dimensioned to receive a plurality of fasteners (not shown) to facilitate connection of the panel 1000 to the edifice, as discussed in further detail below. In certain embodiments, the height H1 may be within the range of 3-6, whereas the height H2 may be within the range of 4-7. In alternate embodiments of the disclosure, however, the arms 302, 304 may be dimensioned such that H1 and H2 are equal, or such that H1 exceeds H2. While the clip 300 has been described with reference to specific ranges of dimensions, it should be understood that these dimensions are merely illustrative and that the subject matter of the present disclosure is compatible with other, additional dimensions.

[0056] The outer arm 302 includes an outer surface 310 having a plurality of connectors 312 that are configured and dimensioned for mating engagement with the connectors 112 (FIGS. 1, 2) included on the inner surface 108 of the outer pane 104. For example, the connectors 312, 112 may be configured and dimensioned for mechanical engagement, or may be fused together, e.g., by the application of heat, as discussed above. As seen in FIG. 1, mating engagement of the connectors 312, 112, respectively, included on the outer pane 104 and the outer arm 302 of the clip 300 extends the channel 114.

[0057] The connectors 312 included on the clip 300 may vary in size, e.g., diameter. In one particular embodiment, for example, the connectors 312 each define a diameter of . The present disclosure also contemplates connectors 312 defining larger or smaller diameters. Additionally, although illustrated as being identical in configuration and dimensions, the present disclosure also contemplates the incorporation of connectors 312 that may vary in configuration and/or dimensions.

[0058] In one embodiment of the disclosure, the arms 302, 304 each define a thickness of 3/16. In alternate embodiments, however, the thickness of the arms 302, 304, may be varied, without departing from the scope of the present disclosure, to suit a particular need or construction.

[0059] As seen in FIGS. 3 and 4, the arms 302, 304 and the saddle 306 collectively define upper and lower chambers 314, 316 that are located on opposite sides of saddle 306. The saddle 306 connects the arms 302, 304 and defines a span S that is dimensioned to accommodate the insulator 200 such that the insulator 200 is securely positionable between the arms 302, 304, i.e., within the lower chamber 316, as seen in FIG. 1. Consequently, the span S defined by the saddle 306 will generally correspond to the thickness T (FIG. 2) defined by the insulator 200. For example, in the embodiment of the disclosure illustrated in FIGS. 1 and 2, the span S is approximately 3, but may vary from 1.5-6 in alternate embodiments of the disclosure.

[0060] With reference now to FIGS. 5-7, each panel 1000 defines an overall length LS (FIG. 5), a height HS (FIG. 6), and a width WS (FIG. 6). The height HS (FIG. 6) is measured from the bottom of the insulator 200 to the midpoint of the saddle 306. In various embodiments, these dimensions provide sufficient stability and rigidity to resist forces applied to the panels 1000, e.g., via wind, seismic activity, or other lateral forces, thereby limiting, if not entirely obviating, the need for additional strapping. The length LS and the height HS of the panel 1000 may be varied, or cut to size, however, depending on the particular application in which the panel 1000 is employed. Additionally, the width WS of the panel 1000 is customizable depending on the intended use of the panel 1000, and the insulative value that is desired. For example, in those instances requiring added insulative value, the span S (FIG. 3) of the saddle 306 may be increased so as to accommodate increased thickness T in the insulator 200.

[0061] As seen in FIGS. 5-7, a series of panels 1000 may be connected to form an insulative system, or wall W. Specifically, each insulator 200 extends beyond, i.e., below, the panes 102, 104 of the corresponding panel 1000 such that a lower portion P (FIGS. 1, 2, 6, 7) is positionable within the upper chamber 314 defined by the clip 300 of an adjacent panel 1000. In FIG. 5, the dashed lines depict the edges of clips 300 concealed within the panes of the panels 1000. The lower portion P of the insulator 200 can then be connected to the clip 300, e.g., via pressure fitting and/or sealing with an adhesive, such as contact cement or silicone adhesive. By stacking the panels 1000, the height of the wall W can be customized according to the requirements of any insulative application.

[0062] The panels 1000 are manufactured through a molding process, e.g., injection molding. Specifically, a first mold is utilized to form the panes 102, 104 (FIGS. 1, 2), which can then be positioned in mating engagement in the manner discussed above, e.g., by fusing the connectors 110 on the inner pane 102 with the connectors 112 on the outer pane 104. After engagement of the panes 102, 104, the assembled panes 102, 104 are laminated with the insulator 200, e.g., via an adhesive, such as contact cement. In an exemplary assembly process, at a first step the inner pane 102 is laminated to the insulator 200. At a second step, the clip 300 is pressure fitted to the insulator 200. Then, the connectors 112 of outer pane 104 are simultaneously fused to the connectors 110 of inner pane 102 and to the connectors 312 of the clip 300.

[0063] A second mold is utilized to form the clip 300, which can be secured to the assembly of the panes 102, 104 and the insulator 200, e.g., via pressure-fitting and sealing at the interface between the insulator 200 and the clip 300, and at the interface between the clip 300 and the inner pane 102.

[0064] With reference now to FIGS. 5-7, use and installation of the insulative panels 1000 will be described. Initially, after framing and sheathing has been completed, a starter track F (FIG. 5) is installed using a laser level across the bottom of a wall. As used in the present disclosure, a starter track is a portion of the system for insulating an edifice that is configured to secure insulative panels 1000 to the foundation wall of the edifice. For brick applications, a steel angle must be installed at the floor header or foundation wall to support brick. A panel 1000 is then installed horizontally over the starter track, i.e., such that the length LS of the panel 1000 is oriented in generally parallel relation to the ground. The panel 1000 is then secured to the edifice using one or more fasteners (not shown), e.g., screws. For example, the panel 1000 may be fastened via the placement of screws through the extension 308 (see also FIG. 3) defined by the inner arm 304, which is then overlaid with another panel 1000 upon positioning of the insulator 200 within the upper chamber 314, which reduces thermal bridging through mechanical fasteners to the edifice. The simplicity of the installation process drastically reduces the required labor, thereby reducing the overall cost of the build.

[0065] Corners and windows are pressure-fitted and sealed, e.g., with thermal mastic, caulking, or the like, and at the eaves level, flashing is installed on the overhang framing sandwiching the panels 1000 against the wall framing, and is thereafter sealed, e.g., with thermal mastic, caulking, or the like.

[0066] In an embodiment, seams are then sealed with a water-impermeable membrane to maximize moisture resistance, and application of siding, brick, and the like can begin.

[0067] With reference now to FIGS. 8-10, a further starter track 400 will be discussed. The starter track 400 is configured, dimensioned, and adapted to receive insulative panels 1000 including the panes 102, 104 (FIGS. 1, 2) and the insulator 200, and to secure these panels to the foundation wall of the edifice. The starter track 400 may be formed from any material suitable for this intended purpose. For example, the starter track 400 may be formed from the same material as the panes 102, 104, e.g., PET, or alternatively, the starter track 400 may be formed from a different material, e.g., acrylonitrile butadiene styrene (ABS) or the like. To maximize efficiency of the insulative panel 1000 (FIGS. 1, 2), it is envisioned that the starter track 400 may also be formed from a material that limits heat conduction.

[0068] The clip 400 includes an outer arm 404, an intermediate arm 408, an inner arm 412, and a saddle 416. The outer arm 404 and the intermediate arm 408 define a height L7, and the inner arm 412 defines a height L3. In the embodiment illustrated in FIGS. 8 and 9, the arms 404, 408, and 412 are dimensioned such that the height L3 exceeds the height L7 so as to define an extension 414. Extension 414 is configured and dimensioned to receive a plurality of fasteners (not shown) to facilitate connection of the panel 1000 to an exterior base of the foundation wall of the edifice, as discussed in further detail below. For example, an illustrative height L7 is in the range of 2 to 4, whereas an illustrative height L3 is 4 9/16 In alternate embodiments of the disclosure, however, the arms 404, 408, and 412 may be dimensioned such that L7 and L3 are equal, or such that L7 exceeds L3. In the illustrated embodiment, the total length L1 of the saddle 416 may be approximately 4. In the illustrated embodiment, the outer arm 404, intermediate arm 408, and inner arm 412 may have a thickness L6 of about 3/16.

[0069] As seen in FIGS. 8 and 9, the outer arm 404, intermediate arm 408, and the saddle 416 collectively define an outer chamber 424 located above saddle 416 on an outer portion of starter track 400. The intermediate arm 408, inner arm 412, and the saddle 416 collectively define an inner chamber 428 located above saddle 416 at an inner portion of starter track 400.

[0070] The saddle 416 connects the arms 408, 412 and defines a span L2 that is dimensioned to accommodate the insulator 200 such that a lowermost portion of the insulator 200 of the panel 1000 is securely positionable between the arms 408, 412, i.e., within the inner chamber 428, as seen in FIG. 10. Consequently, the span L2 defined between the arms 408 and 412 above the saddle 416 will generally correspond to the thickness T (FIG. 2) defined by the insulator 200. For example, in the embodiment of the disclosure illustrated in FIGS. 1 and 2, the span L2 is approximately 3, but may vary from 1-12 in alternate embodiments of the disclosure.

[0071] As seen in FIG. 10, a lowermost portion of the insulator 200 is received within the inner channel 428 of starter track 400. As seen in FIG. 9, the saddle 416 includes an upper surface between arms 408, 412, and may include a plurality of dimples 420. If included, dimples 420 are configured to support the insulator 200 above the upper surface of saddle 416 between arms 408, 412 to allow for efficient drainage from insulator 200.

[0072] The saddle 416 connects the arms 404, 408 and defines a span L5 that is dimensioned to accommodate the joined inner and outer panes 102, 104 of the panel 1000. A lowermost portion of the inner and outer panes 102, 104 is received between the arms 404, 414, i.e., within the outer chamber 424, as seen in FIG. 10. Consequently, the span L5 defined between the arms 404 and 408 above the saddle 416 will generally correspond to a thickness defined by the joined inner and outer panes 102, 104.

[0073] As seen in FIG. 10, a series of panels 1000 may be connected to form an insulative system, or wall W, with a lowermost panel 1000 fastened within the starter track 400, which acts as the first saddle for the interconnected series of panels. In an embodiment, the starter track 400 is fastened to the exterior base of the foundation wall of an edifice. A series of starter tracks 400 may be installed around the foundation perimeter of the edifice surface to be cladded.

[0074] In an embodiment, the starter track 400 serves as flashing, and is formed of a water-impervious material that provides a weather-resistant barrier. In certain embodiments, a series of weep holes 436 are spaced along the base of intermediate arm 408, and a series of weep holes 432 are spaced along the base of outer arm 404, to allow water to drain from the chamber 428 containing the insulator 200, and to drain from the chamber 424 containing the inner and outer panes 102, 104. The starter track 400 also includes a graded drainage panel 440 that provides positive drainage away from the starter track and from the panels 1000 anchored at the starter track. In an exemplary embodiment, the drainage panel has a length L4 of approximately 1, and the weep holes 432, 436 have a diameter of around . In certain embodiments, the angle between inner arm 412 and saddle 416 is increased (to an angle above 90) in order to improve drainage.

[0075] While the starter track 400 has been described with reference to specific dimensions and ranges of dimensions, it should be understood that these dimensions are merely illustrative and that the subject matter of the present disclosure is compatible with other, additional dimensions.

[0076] While the present disclosure has been described in connection with specific, illustrative embodiments, it should be understood that the subject matter of the present disclosure is capable of further modifications. For example, persons skilled in the art will understand that additional components and features may be added to any of the embodiments discussed herein above, and that those elements and features described in connection with any one embodiment may also be applicable to, or combined with, those of any other embodiment without departing from the scope of the present disclosure.

[0077] The scope of the present disclosure is intended to cover any variations, uses, and/or adaptations of the presently disclosed subject matter in accordance with the principles of the present disclosure, including such departures from the present disclosure as come within known or customary practice within the art to which the present disclosure pertains, and as may be applied to the elements, components, and features set forth herein above.