NZ243958A

NZ243958A - Collapsible insulation material: multiple layers of insulating material connected by collapsible supports and defining at least two cavities

Info

Publication number: NZ243958A
Application number: NZ243958A
Authority: NZ
Inventors: Ralph Warwick Skoien
Original assignee: Ralph Warwick Skoien
Priority date: 1991-08-14
Filing date: 1992-08-14
Publication date: 1995-07-26
Also published as: IL102780A; WO1993004240A1; MY110319A

Description

24 39 bB Priori-/ K)ftte(9):.

Specijteetion Fllftd: ' nine*: (5).. EQkfc.'./.lit*..£ Ifew55?/P.& h'bo.^-jjc, u-, qjt <••«•»••«••••••••••••••• »rl • /» «»« l •••#«•••• ••• ' 2 « JUl SB | '".^♦callon Dnie: J \0. Journal, No: ..... taa>*;~ ■ \ Patents Form No. 5 14 AK ;:32 NEW ZEALAND PATENTS ACT 1953 COMPLETE SPECIFICATION REFLECTIVE INSULATION BATTS I, RALPH WARWICK SKOIEN, an Australian citizen of 53 Grove Road, Rosanna, Victoria 3084, AUSTRALIA hereby declare the invention, for which I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the following statement: (followed by page la) -1a- REFLECTIVE INSULATION BATTS This invention relates to an improved insulation batt of reflective insulating material.

Australian patent specification 15584/76 proposes an insulating batt 5 having at least two substantially flat, self-supporting sheets of reflective insulating material, secured in substantially parallel overlapping relationship. The at least two sheets are secured in such relationship by at least two substantially parallel strips extending between, and secured to, those sheets. The arrangement is such that the batt can be adjusted between a collapsed 10 position in which, by bending of the strips along fold lines, the sheets are in substantially face to face relation, and an expanded position in which the at least two sheets are spaced by webs of the strips.

The broad disclosure of specification 15584/76 refers to the batts as having at least two sheets secured by such strips. However, the batts 15 specifically shown therein have only two sheets.

Insulating batts of the type shown in specification 15584/76 have had good commercial acceptance. While they have comprised only two sheets of reflective insulating material, they are found to provide a good level of thermal insulation. However, while a batt of that general type which has more than two 20 sheets would be capable of providing even better insulating characteristics, it is not suitable for commercial production. Thus, while a batt as in specification 15584/76, with more than two sheets, can be assembled by hand, or by overlaying and bonding of two batts each of two sheets to provide a batt assembly of three effective sheets, these modes of manufacture are not 25 economic.

The present invention is directed to providing an improved form of insulating batt which is amenable to automated production.

According to the invention, there is provided an insulating batt comprising two sheets of heat reflective insulating material and connecting 30 means provided between said sheets and (followed by page 2) > 2- ^ connecting said sheets together in an overlapping, substantially parallel relationship; said connecting means enabling said batt to be adjusted between a collapsed configuration in which said sheets are closely adjacent, and an operative configuration in which said sheets are spaced from each other by 5 said connecting means; wherein, said connecting means comprises: (a) a plurality of substantially parallel, mutually spaced bracing strips extending between and connected to each of said sheets, each bracing strip having two substantially parallel longitudinal fold lines such that a bracing web is defined between said lines and a respective side margin extends from the bracing web beyond each fold line, each of the bracing strips having a respective side margin secured to each of said sheets such that the bracing web is substantially normal to and defines the spacing between the sheets when said batt is in its operative configuration and such that, on movement of the batt to its collapsed configuration, the bracing webs are substantially 15 parallel to the sheets; and (b) a plurality of partition strips of heat reflective insulating material, each of which extends longitudinally between the webs of successive bracing strips, each partition strip being folded along two substantially parallel fold lines such that a central partition web is defined between said fold lines and a respective side flange extends from the partition web beyond each of its fold lines, each of the partition strips having a respective side flange secured to a respective web of said successive bracing strips, the width of the partition web substantially corresponding to the spacing between said successive bracing strips when said batt is in its operative configuration such that, on movement of the batt from its 25 operative configuration to its collapsed configuration, each partition web is spaced from and preferably is substantially parallel to each of the sheets.

In the following description, the "collapsed configuration" and the "operative configuration" are referred to as respective positions.

An insulating batt according to the invention preferably is rectangular 30 and comprises two rectangular sheets of heat reflecting material secured in overlapping, substantially parallel relationship, and connecting means provided between the two sheets to connect the sheets in that relationship. The connecting means enable the batt to be adjusted between a collapsed position in which the 5 two sheets are closely adjacent, and an operative position in which the two sheets are spaced from each other by the connecting means. In the operative position, the connecting means and the sheets define a plurality of air cavities which extend in substantially parallel 10 relationship between a first pair of opposed edges of the batt, with the air cavities being in at least two layers thereof intermediate the sheets.

As indicated, in the batt according to the invention# the two sheets preferably are of rectangular 15 form, such that the batt overall is of that form. For ease of description, this is assumed in the following, although it will become apparent that other forms are possible, even though less practical. Also, for ease of description, the opposed edges of the batt between which 20 the air cavities extend will hereinafter be designated as ends or opposed ends, with edges extending between the ends being designated as opposed sides or sides, although the converse can apply.

The connecting means comprises a plurality of 25 sustantially parallel bracing strips which extend between and are connected to each of the two sheets. The bracing strips are mutually spaced across the width of the batt between the opposed sides, with the spacing preferably being substantially uniform. The bracing strips 30 preferably have a length substantially equal to the length of the batt between the opposed ends. While a lesser length of the bracing strips is possible, it is highly desirable that their length is a major part, such as at least 85%, of the length of the batt.

Each bracing strip is folded along two substantially parallel longitudinal fold lines, such that it defines a bracing web between those lines and a respective side margin extending from the bracing web beyond each fold line. Each bracing strip has a respective one of its side J Z j l> 3 O margins bonded to each of the two sheets such that the bracing web is substantially normal to the sheets with the batt in its operative position and the width of the bracing web between the fold lines defines the spacing 5 between the sheets. The arrangement of the bracing strips is such that, on movement of the batt from its operative position to its collapsed position, the bracing strips bend at the fold lines such that the bracing strips extend between and become substantially parallel to the two 10 sheets.

The connecting means further comprises a plurality of partition strips, each of which extends longitudinally between and is connected to the webs of successive bracing strips intermediate the fold lines of the bracing strips. 15 Each partition strip is folded along two substantially parallel fold lines, such that it defines a central partition web between its fold lines, and a respective side flange extending from the partition web beyond each of its fold lines. Each partition strip has a respective 20 one of its side flanges bonded to each of the bracing webs of its successive bracing strips, with the width of the partition web between its fold lines substantially corresponding to the spacing between the successive bracing webs with the batt in its operative position. The 25 partition strips extend in substantially parallel relationship to the bracing strips and preferably have a length substantially equal to the length of the bracing strips between the opposed ends of the batt. The arrangement of the partition strips is such that, on 30 movement of the batt from its operative position to its collapsed position, each partition strip bends at its fold lines so as to adjust from a configuration in which its partition web extends between its successive bracing webs, intermediate the two sheets, to a configuration in which 35 its partition web extends between and substantially parallel to the two sheets.

With the batt in its operative position, the partition web of each partition strip preferably is substantially parallel to the two sheets. In one form, a single partition strip is provided between each set of successive bracing strips. In that form, the bracing strips preferably are positioned such that all partition webs are substantially co-planar when the batt is in its operative position. In an alternative form, a plurality of partition strips, most preferably two or three, is 5 provided between each set of successive bracing strips. In that alternative, the partition webs between each of successive bracing webs are mutually spaced from each other and from the two sheets, with the partition webs most preferably substantially parallel to the two sheets, when the batt is in its operative position. Also in that alternative, with the batt in its operative position, 10 each partition web between each of the successive bracing webs preferably is substantially co-planar with a respective partition web between each other set of the successive bracing webs.

While the batt of the invention requires only the two sheets, the partition webs therebetween function as at least one further such sheet. However, due 15 to provision of respective partition strips, manufacture of the batt in an economic manner is made possible, in contrast to a batt which has three or more sheets as permitted by specification 15584/76.

The two sheets, and at least the partition strips of the connecting means, are formed of a heat reflective insulating material. These may, for example, 20 comprise at least one layer of paper, preferably coated or impregnated with a bituminous or fire resistant material, and having a reflective metal film or foil over at least one surface thereof. Such material having such film or foil over only one surface is sufficient, although it is preferred to have at least one of the two sheets provided with a reflective metal film or foil over each of its surfaces. 25 The bracing webs of the connecting means may be of similar material.

There is benefjt in having the bracing webs of heat reflective material, although this is not imperative. However, it is required that the bracing strips are such that, on moving the batt from its '£L\ J V# collapsed position, in which it is typically produced, to its operative position, the bracing strips retain the batt in its operative position with the batt in its normal, in use, horizontally disposed orientation.

In order that the invention may more readily be understood, description now is directed to the accompanying drawings, in which: Figure 1 shows a first form of insulating batt according to the invention, in its normal, in use 10 operative position; Figure 2 shows the batt of Figure 1 in its as formed, collapsed position; and Figure 3 corresponds to Figure 1 but shows a second form of batt according to the invention.

The batt 10 of Figures 1 and 2 has upper and lower rectangular sheets 12,14 and connecting means 16 securing sheets 12,14 in substantially parallel, overlapping relationship. Connecting means 16 includes a plurality of parallel bracing strips 18, which are uniformly spaced 20 laterally of sheets 12,14, and a plurality of partition strips 20. The length of strips 18 and of strips 20 correspond substantially to the length of batt 10.

In the operative position of batt 10, as shown in Figure 1, strips 18 are of channel section. Each has a 25 central bracing web 18a bordered along each side thereof by a respective side margin 18b, with a fold line 18c at the junction of each side of web 18a and the respective margin 18b.

Between each web 18a and the web of the next 30 successive strip 18, there is provided a respective one of the partitions strips 20. Each of strips 20 is of channel section somewhat similar to strips 18, to define a partition web 20a, side flanges 20b and fold lines 20c.

Each of side margins 18b is bonded along an inner 35 surface of a respective one of sheets 12,14 such that with the batt in the position shown in Figure 1, sheets 12,14 are spaced by webs 18a, with the latter substantially perpendicular to sheets 12,14. Also, each side flange 20b is bonded along a surface of a respective web 18a, such :) j j u that each partition web 20a extends between successive webs 18a, intermediate and substantially parallel to sheets 12,14.

Batt 10 is formed by first bonding a respective 5 margin 18b of each strip 18 along a first one of sheets 12,14. With the strips 18 lying against that first sheet, a side flange 20b of each strip 20 then is bonded to the upper-most surface of the webs 18a of all but one of the laterally outermost strips 18. The strips 18 then are 10 folded through 180° along the fold line 18c adjacent the bonded margin 18b, to bring the other surface of webs 18a uppermost, after which each other flange 20b is bonded to the next successive web 18a and the other side margins 18b are bonded to the second one of sheets 12,14. 15 This succession of operations produces batt 10 in the collapsed condition shown in Figure 2. In that condition, sheets 12,14 are closely adjacent, with webs 18a,20a lying flat therebetween. As shown, sheets 12,14 are laterally offset in that condition but, by gripping 20 the right side of sheet 12 and the left side of sheet 14, and laterally pulling the sheets in opposite directions, batt 10 is moved to the position shown in Figure 1, with sheets 12,14 spaced by webs 18a.

Sheets 12,14 and strips 18,20 are formed of paper 25 having a heat reflective metal foil or film over at least one surface thereof. Upper sheet 12 preferably has foil or film over each of its surfaces. Lower sheet 14 and strips 18,20 preferably have foil or film over only one surface, with bonding of strips 18,20 to sheets 12,14 most 30 preferably being at surfaces of strips 18,20 not provided with such foil or film.

The batt 30 of Figure 3 readily will be understood from the description of batt 10 of Figures 1 and 2. Batt 30 differs in that the width of webs 18a and hence, the 35 spacing of sheets 12,14 is greater than in batt 10. Also, batt 30 is provided with two partition strips 20 between successive webs 18a, with their webs 20a substantially parallel and spaced from each other and from sheets 12,14.

The method of producing batt 30 also will be readily understood from the description with reference to Figures 1 and 2. However, in this instance, the flanges 20b of the two strips 20 are in turn bonded first to one of its webs 18a and then to the other of its webs 18a, followed 5 by bonding of the other of margins 18b to the second one of sheets 12,14. Again, batt 30 as formed, is in its collapsed condition, but is brought to the position shown in Figure 3 in the manner described for batt 10.

While the strips 18 are of channel section in the 10 positions shown in Figures 1 and 3, i.e. of C-shape in cross-section, this is not necessarily the case. Thus, strips 18 can be Z-shape in cross-section. Similarly, strips 20 are shown as being of C-shape in cross-section, as is preferred, but they also can be of Z-shape in 15 cross-section. Overall, it is highly preferred that bonding between surfaces of strips 18 and each of sheets 12,14 and strips 20 is between surfaces of which at least one is of paper.

In each of Figures 1 and 3, the partition webs 20a 20 are shown as co-planar or in co-planar sets. This is preferred for ease of manufacture, but is not essential. Indeed, where the batt 10 or 30 is to provide thermal insulation against a heat source which is not perpendicular to a necessary orientation of sheets 12,14, 25 it can be beneficial to have at least some of webs 20a inclined with respect to sheets 12,14 so that the webs 20a face towards the heat source. In the latter case, all webs 20a can be similarly inclined, such as to be substantially parallel to each other.

Batts 10,30 are found to be self-supporting when in the position of Figures 1 and 3. However/ as shown in Figure 1, at least one tab 22 can be turned from at least one of sheets 12,14, so as to abut against an adjacent web 18a, to provide a locking action.

Batts 10,30 are well suited for in ceiling insulation. In such application, they typically are laid across, rather than between, ceiling joists. However, the batts also can be used in other applications, such as in cavity walls, between studs and facing sheets, with sheets -9- £4 ^'38 12,14 substantially vertical.

The batts 10,30 provide significantly improved thermal insulation relative to a two-sheet batt of specification 15584/76 made of similar sheet materials. Thus, for batts having an upper sheet having foil on each surface and a lower 5 sheet having foil on only one surface, the batt of specification 15584/76 can exhibit R values of 4.1 in summer and 1.4 in winter. Again, using such upper and lower layers, a batt 10 as in Figure 1 can achieve R values of 5.5 in summer and 2.7 in winter, while corresponding values for batt 30 of Figure 3 are 6.8 and 3.5. The R value is an internationally accepted measure of thermal 10 resistance, with higher values indicating greater thermal efficiency.

Finally it is to be understood that various alterations, modifications and/or additions may be introduced into the constructions and arrangements of parts previously described without departing from the spirit or ambit of the invention, as defined by the following claims.

H-7. r vrr? OFFICE '3 APR 1335 i

Claims

WHAT WE CLAIM IS:

1 An insulating batt comprising two sheets of heat reflective insulating material and connecting means provided between said sheets and connecting said sheets together in an overlapping, substantially parallel relationship; said 5 connecting means enabling said batt to be adjusted between a collapsed configuration in which said sheets are closely adjacent, and an operative configuration in which said sheets are spaced from each other by said connecting means; wherein, said connecting means comprises: (a) a plurality of substantially parallel, mutually spaced bracing strips 10 extending between and connected to each of said sheets, each bracing strip having two substantially parallel longitudinal fold lines such that a bracing web is defined between said lines and a respective side margin extends from the bracing web beyond each fold line, each of the bracing strips having a respective side margin secured to each of said sheets such that the bracing 15 web is substantially normal to and defines the spacing between the sheets when said batt is in its operative configuration and such that, on movement of the batt to its collapsed configuration, the bracing webs are substantially parallel to the sheets; and (b) a plurality of partition strips of heat reflective insulating material, each of 20 which extends longitudinally between the webs of successive bracing strips, each partition strip being folded along two substantially parallel fold lines such that a central partition web is defined between said fold lines and a respective side flange extends from the partition web beyond each of its fold lines, each of the partition strips having a respective side flange secured to a respective web 25 of said successive bracing strips, the width of the partition web substantially corresponding to the spacing between said successive bracing strips when said batt is in its operative configuration such that, on movement of the batt from its operative configuration to its collapsed configuration, each partition web is spaced from each of the sheets. 30

2. The batt of claim 1, wherein said batt has a rectangular shape, and wherein the bracing strips are substantially uniformly spaced laterally of the batt. -11- ^ ^30

3. The batt of claim 2, wherein the bracing strips have a length which is at least 85% of the length of the batt.

4 The batt of claim 2, wherein the bracing strips have a length substantially equal to the length of the batt.

5 5 The batt of any one of claims 1 to 4, wherein the partition strips have a length substantially equal to the length of the bracing strips.

6. The batt of any one of claims 1 to 5, wherein the partition web of each partition strip is substantially parallel to the two sheets when said batt is in its operative configuration. 10

7. The batt of any one of claims 1 to 5, wherein at least some of the partition webs are inclined with respect to the two sheets when said batt is in its operative configuration.

8. The batt of any of claims 1 to 7, wherein a single partition strip is provided between said webs of said successive bracing strips. 15

9. The batt of any one of claims 1 to 7, wherein a plurality of partition strips is provided between said webs of said successive bracing strips, said plurality of partition strips being spaced from each other and from said two sheets when said batt is in its operative configuration.

10. The batt of claim 9, wherein two partition strips are provided between 20 said webs of said successive bracing strips.

11. The batt of claim 9, wherein three partition strips are provided between said webs of said successive bracing strips.

12. The batt of any one of claims 1 to 11, wherein each partition web between each of the successive bracing webs is substantially co-planar with a 25 respective partition web between each other set of the successive bracing webs, when said batt is in said operative configuration.

13. The batt of any of claims 1 to 12, wherein said heat reflective, insulating material comprises at least one layer of paper having a reflective metal film or foil over at least one surface thereof. 30

14. The batt of claim 13, wherein said at least one layer of paper is coated or impregnated with a bituminous or fire resistant material. 7~1 -12- 25 *43558

15. The batt of claim 13 or claim 14, wherein at least one of said two sheets is provided with said reflective metal film or foil over each surface thereof.

16. The batt of any one of claims 1 to 15, wherein said bracing webs are of 5 said heat reflective, insulating material.

17. The batt of any one of claims 1 to 16, wherein at least one of said bracing strips and/or said partition strips has a C-shaped cross-section when said batt is in its operative configuration.

18. The batt of any one of claims 1 to 16, wherein at least one of said 10 bracing strips and/or said partition strips has a Z-shaped cross-section when said batt is in its operative configuration.

19. The batt of any one of claims 1 to 18, wherein securement of said bracing strips to said two sheets and to said partition strips is by adhesive bonding therebetween. 15

20. The batt of any one of claims 1 to 19, wherein at least one of said sheets is provided with at least one foldable locking tab for locking said batt in its operative configuration.

21. The batt of any one of claims 1 to 20, wherein the web of each partition strip is substantially parallel to the two sheets when said batt is in its operative 20 configuration.

22. A method of forming an insulating batt substantially as herein described with reference to the accompanying drawings.

23. An insulating batt substantially as herein described with reference to the accompanying drawings. RALPH WARWICK SKOIEN By his Attorneys BALDWIN SON & CAREY '/■'rVt' \ 30 i J