US2335220A - Building insulation - Google Patents

Description

'NOW 23, 1943 G. E. EDWARDS BUILDING INSULATION Filed April 21, 1941 Gle/F7077# E Eon/Meca BY Y ' Patented Nov. 23, 1943 i UNITED .STATES PATENT ori-lcs BUILDING INSULATION Grimm E. Edwards, Whiteman Bay, wis.,

assignor to Walter M. Ericson, Milwaukee, Wis. @puatron April zi, 1941, serieu No. 389,544

zo claims. (ci. 154-44) spacing: and particularly the provision oi a bat 'I'his invention relates building insulation.

It is the primary object oi.' the invention to provide a novel and improved form-sustaining to improvements in bat which is readily handled, which provides a' tight seal between the studs irrespective of minor deviations from standard ,spacing and which, notwithstandingthe use of stitching for holding the bat in shape, maintains a vapor-tight seal which is substantially continuous throughout the entire surface insulated. u

With respect to handling, `it is desirable that the bat should have a vcompression t between.

the studs and consequently lateral compressibility is desired; yet it is desirable that the bat should be so rigid or stift in a longitudinal direction that it can readily be lifted and manipulated without folding or collapsing. The combination of longitudinal stiffness with lateral compressibility is an important objective of the present invention achieved by a. longitudinal trussing eiiect produced by the construction hereinafter to be de- I prefer to maintain the form of the bat by rows of stitching extending longitudinally thereof and traversing not only the bat but the plies of paper board above and below the bat, and it Y bonding agent in the ber. In this connection is an object to so form the paper board as to preserve lateral compressibility of the product while .at the same time providing the necessary vapor seal and assuring longitudinal stiffness.

More specically stated, other objects ci the invention are: the provision of an insulating bat having aditlerential in stillness as Vbetween its mounting face and its inner face, the mounting face being the more Vrigid whereby the mounting faces -of successive bats may be overlapped to provide a continuous seal. the inner i'acesof the respective bats being suiliciently collapsible to permit .of an 'overlap of the outer face despite the fact that theinner and outeriaces are initially of the same dimensions; the provision of a bat of wedge-shaped form which is deformable to provide a close t betweenstuds which are either at insuicient spacing or at excessive in which the mechanical stitching of the insulation bat is accomplished independently of. and

vprotected by, an vimpervious unstitched vaportioned, and stili other objects will be apparent from thel specication. Inthe drawing:

Fig. 1 is a fragmentary ,view in perspective showing building insulation embodying my invention.

Fig. Bis an enlarged detailwiewiin section through an insulating bat embodying the invention. i

modified embodiment oi the invention;

Fig.`4 is a fragmentary detail view injvertical' section showing the manner in which successive bats are overlapped in sealed relation. Like parts are identied by the same reference characters throughout the several views.

'I'he studding 5 and the sheathing 6 are conventional, the studs usually being approximately spaced on predetermined centers. However, the

studs are sometimes slightly greater or less than standard distances between studs.

The bat properV 1, is preferably brous but Aa f wide variety, 0i insulating material may be used. For example, the bat I may consist of rock wool,

glass ber, asbestos, small paper akes, wood ber, hair, or cane ber, etc. I have use'd to advantage a homogeneous mixture of bers having resilience as well as cohesion, short y ber of wood or bark being mixed with asbestos or the like and later having long bers of wood,

Y -`.bark, cotton. hair, or other material introduced into the mixture to provide resilience, while re- -taining the cohesion.

Preferably, I use a shredded redwood bark ber either in its natural stain (in which it is highly lire resistant) or with a reproong coating added. Since the invention as herein set forth is vindependentof the particular materials used,

it will be Aunderstood that the materials vabove specified are merely illustrative.

The bat 'I is conned between a cover ply l and a enamel DI! which comprises a back 9. out-- wardly converging sides l0. and lateral anges si; tnegcover ply va and .bacs s being united Fig. 3 is a view similar to Fig. 2 showinga through the bat by longitudinal rows of stitching at I2. The face ply 8 and the channel ply comprising the back 9, sides III, and flanges II, preferably comprise strong paper such as mailt paper, and I prefer to use about four rows of stitching I2 lengthwiseof the standard bat.

The stitching is incorporated under sumcient tension yto compress the bat slightly along the lines of-stitching. The rows of stitching divide the channel and cover ply S into a. series of pockets extending longitudinally of the device. Within these pockets the brous material of the bat is free for expansion and compression with its natural resilience virtually unimpeded. The back wall 9 of the channel will preferably bulge slightly between the side walls lil and between the successive rows of stitching at I2, as clearly indicated in Fig. 2, and this bulging will be somewhat accentuated when the device is deformed for insertion between studs inthe manner shown in. Fig. 1, The slight initial bulging facilitates the lateral compression of the product.

The flanges I I and the cover ply 8 are substantially in the same plane and are reinforced by an additional ply or plies constituting facing or mountingV web and providing a vapor seal. These may constitute sheets il and it of kraft paper and an intervening ply of asphaltum as indicated at I9 in Fig. 2, o r, alternatively, I may employ a single ply EE of kraft paper and a. thin coat of asphaltum (or aluminum foil, or plastic varnish, or other impervious material) at 20 as shown in Fig. 3, the impervious coat being protected within y the outer ply I8 of paper. Regardless of whether the facing or mounting and vapor sealing plies are made in accordance with the disclosure ofA Fig. 2 lor the `disclosure of Fig. 3, they are in either case treated with ribbons of plastic adhesive. preferably'of a waterproof nature, such as hot asphaltum, such ribbons being applied at apanage 8 and 8 and to prevent any tearing orslippingof the threads. The bonding cementitious ribbons I5 and I6 are preferably carefully metered as to thickness to be of uniform thickness throughout so that the resulting product will be smooth and free or eccentric bulging and will be of uniform exibility.

Asphaltum is an ideal adhesive for the pur-l poses of the present invention since it is thermoplastic and may readily be conditioned for appli- -cation in relatively thick ribbons to provide the l5 over each ange II and at I6 over each row of stitching I2 lso that when the vapor seal ply or plies are assembled onto the batand channel the bat will be encased Vin a strong envelope from the back of .which vapor may escape but the front or mounting face of which will be substantially impervious to vapor.. The ribbons of hot asphaltum could be applied directly .to the flanges II and the cover ply 8, but -inaccordance witha method application hereinafter to be filed, I have found it advantageous to apply the asphaltum in the first instance to the facing or mounting web at such intervals as to cverlie the areas to which adhesion of the mounting web is desired.

I have found that the combination of the mounting web and the cover ply 8 and the chan- 'mote from such flanges. y

the i width of the channel is preferably slightly nel flanges II, with intervening ribbons of asphaltum has a truss-like action contributing :materially to the desired longitudinal stiffness, while permitting, due to the space between such ribbons, the desired lateral compressibility.

The ply I8, together with plies I1 and I9, or 20, as the case may be, are bonded by the adhesive ribbons I6 to `the cover plv 8 ofthe bat andl also to the flanges Il of the channel withindesired truss effect in conjunction with the rows oi stitching. After application, the adhesive becomes fairly rigid without being so rigid as to crack. In actual practice the asphaltum is subjected to very little bending. vThe product is relatively stiif in a longitudinal direction, requiring no bending longitudinally in normal application. Such yielding as is involved in the lateral compressibility is accommodated by the deformation of bat material which lies in the pockets between the stitching and between the rows of asphaltum.

The particular method and apparatus employed in the manufacture of the product are not petinent to the present invention. While I have referred above to the fact that the asphaltum is preferably applied initially to the sealing ply or plies, it will be understood that so far as the present invention is concerned it might be applied in ribbons to the ange II and the cover ply 8. In practice the web of paper providing the channel is formed and lled with the bat in a continuous operation, in the course of which the cover ply 8 is applied over the bat and the stitching is done.

as the assembled bat, channeLa'n'd cover ply advence in the course of such operation, the sealing ply or plies are treated with ribbons of hot as-.i

phaltum which remains plastic until bonded to the flanges of the channel andthe cover ply of the bat.

In the construction shown in Fig. 3 the thin coat of asphaltum, aluminum foil or other impervious material is preferably applied by means of a roller to the web I8 under`pressure, and

thereafter the bonding ribbons are applied thereoiu at I5 and I6, preferably in a separate operat on.

The channeled web within which the bat is confined is of such form, due to the convergence of its sides ill toward its flanged margins, that the channel is relatively narrower adjacent the anges il and is relatively wide at the rear, re-

Adjacent flanges II less than the conventional distance between studs 5. whereas at the rear of the channel the rear wall ply 9 is slightly greater than the conventional distance between studs.

To further enhance the truss effect and therey by contribute to longitudinal stiffness. the rear ply 9 is reinforced by a ply 2l which is preferably made of kraft paper bonded to the channel back ply 9 by means of strips or ribbons of adhesive 22 which, like the similar adhesive ribbon I6, may

simply comprise layers of asphaltu-in. It is not essential to the invention that a vapor seal be provided at the rear face of the bat since the vapor seal provided at the front face is substantially impenetrable to vapor'. The adhesive ribbons 22 anchor the threads used to provide the stitching at I2, as well as holding the reinforcing ply 2I- in place. The reinforcing ply is preferably of materially less width than the rear ply 9 so as The fact that the bat, at its rear face, is ma terially wider than the conventional space be- 3 extending between the sides of the channel across said bat, 'stitching extending through the cover Ply, the bat, and the bottom of the channel, a

' mounting web spanning the cover ply and channel, flange means projecting laterally from the channel and connected to the mounting web and channel, and a waterproof adhesive covering said lstitching and joining said mounting web and II, ensures against any buckling of the bat when the flanges Il are tacked or staple'd to the studs,

even though the studs may-be somewhat closer.

together than is standard. It is important that the greatest width of the wedge-shaped structure isremote from the mounting flanges. If it were directly at the mounting iianges it couldnot yield appreciably without serious buckling of the webs. Being remote from the mounting flanges it can yield despite the fact that the flanges are stretched under tension by the operator in the course of their application tothe i studs.

Due to the multiple plies at the front of the hat, and particularly to the vapor-prooiing comprising either the continuous asphaltum layerA at il or the aluminum foil or asphaltum layer at 20, the front of the bat will have a l considerably greater resistance to distortion than the rear of the bat. This diierential in resistance to distortion is of advantage in the assembly of a plurality of consecutive bats in a single stud or joist space. Instead of merely abutting the ends of the consecutive hats, the end of one or both of the bats including the insulation l, the side walls I0,

therear ply 8, and the rear reinforcingply 2L may be slightly crumpled to an extent suillcientso that the insulation bats will be united under pressure while the several plies comprising the mounting webV and including the anges il and the plies il', i 8 and I9, will overlap as shown in Fig. 4, the face plies being substantially uncrumpled and ilat inA perfect face contact to provide'a continuous vapor seal between the studs,

while the insulation bats provide a substantially stantial rigidity, still retaining, however, lateral compressibility and requiring some pressure for the positioning of the bat between studs, thus assuring a firm and adequate contact and a satisfactory hermetic and vapor seal, as well as thermal insulation.

I claim: Y

1. Building insulation comprising a bat and an enclosure for said bat including a channel and a mounting web, the channel having lateral ilanges amxed to said mounting web `and having sides converging-toward each other in the direcnel having an outer web materially greater in width than the portion of the mounting web intervening between said sides.

2. Thermal insulating comprising a bat of insulating material, a channel having a bottom and sidesbetween which said bat is disposed, the sides of the channel being convergent toward each einer away from said bottom, a cover ply tion o! said mounting web and ilanges, said chancover ply.l

3. Thermal insulation comprising the combinan-l tion with a. channel providedV with a relatively broad base and side walls converging toward each other away from the base, of a hat of thermal insulation within said channel between said walls, a cover plyy at least substantially spanning said bat adjacent thoseportions of said walls which are closest, flange means projecting laterally from said wall portions forpositioning the insulation upon and between building studs, rows of stitching through the coverl ply, the bat, and the base of the channel, adhesive means providing a vapor seal substantially continuously over said rows of stitching, a facing web to which said ilanges are connected, and an extension of such adhesive between the facing web and the cover ply.

4. A thermal insulation device` comprising an elongated bat of brous compressible insulating material, a channel having a base portion and sides converging toward yeach other away from said base portion, stitching connecting the Vbat to the channel, and a facing member having,-

materially greater body than said channel and provided substantially continuously with a vapor sealing vmoisture-prooi. material spanning said bat and channel and covering said stitching and connected with the convergent side portions of said channel along lines remote from the base thereof, whereby said bat is completely enclosed saveat its ends, the end portion of the channel being compressible more readily than said facing member whereby to permit the facing members of longitudinally successive devices to be overlapped when the ends of the channels of suchdevices are compressed into abutment.

5. The device of claim 4 wherein the marginal portions of the convergent sides of the channel are flanged outwardly and said facing member is extended over the outwardly ilanged portions aforesaid and adhesively joined thereto.

6. An insulation device comprising the combination with a relatively heavy mounting member having margins so spaced as to be adapted to be secured to the studs of a standard building structure, of an insulating body carried by said mounting member between its margins and comprising a face remote from said member and sides divergent away from said mounting member, flanges Aon said sides, and means connecting said side flanges in general parallelism to said mounting member, the said face being materially wider than the portion of said mounting member intervening between said sides and the divergence of said sides being such that said sides at points remote from said mounting member are more widely separated than the normal distance between studs, while adjacent said mounting member said sides are at least as narrowly spaced as the normal distance between studs.

7. The ,device of claim 6 wherein the said body is provided with a space between its sides and a hat of insulating material lls such space, and rows of securing stitching pass through said bat and portions o f said body, said rows of stitching being covered with water-resistant material in.

'iihesive connection with said mounting member.

.at angine deviceoficlaim 6V wherein a cover webv lies adiacentlsaid mounting member; a bat of DSUlating materialfills the space between the cover web, the-sides,-.and the meansV connecting said'sides; stitching extends throughsaid cover.

web .and bat and means, and an adhesive material bondsv said cover webto. said member and provides a vapor seal for the bat and said rows of stitching. Y f Y 49.4i. thermal insulating device comprising the combination of? means providing an elongated.

sheath penetrated by said stitching, whereby toassenso provide truss-like reinforcement longitudinaliy of said sheath while permitting said sheath to he compressed in a lateral direction between said rows of stitching and ribbons of adhesive.

10. .An insulating device comprising the combination with an elongated. bat oi insulating material; of a sheath therefor comprising a channel having sides lengaging the sides of the bat, a back engaging the back of the bat and flanges connected with said sides and projecting laterally from the face lof the bat, a cover ply spanning the bat between the sides and anges oi' the channel; stitching extending in longitudinal rows throughthe cover ply, the bat, and the bach of the channel, the bat being conned between the rows of stitching and the channel in wickets wherein the bat retains substantially full natural resilience, amounting web overlying the anges Y and the cover ply, and means adhesively joining the mounting web to the flanges and cover ply,

said means. including longitudinal ribbons oi adhesive overlying the rows of stitching and sealing the stitching while providing reinforcement longitudinally of said device.

l1. An insulating device comprising the combination with a bath, of an elongated sheath enclosing the bath and comprising a channel having a back, sides, and lateral flanges projecting from said sides, and a cover ply spanning the bat between said sides and flanges, stitching in rows Y longitudinally of the bath and the channel tra- 12. 'I'he device of claim 11 wherein the back of` the channel is provided with a backing ply having side margins well within the sides oi the channel, said backing ply being connected to and spaced from the back oi the channel by intervening ribbons of adhesive 'overlying the rows of stitching and `constituting means contributing to the longitudinal sti'ness of the device.

. 13. An insulation device comprising the comspaced therefrom, and side portions extending from said back portion to said mounting web and connected therewith, a bat of insulating material within said channel and spanned by said vapor seal ply, a cover. ply spanning said channel across said batfstitching through the cover ply, the bat andthe back of the channel, and vapor sealing means covering said stitching. A

14. A thermal insulation device comprising a multiple ply backing webinc'luding a plurality of plies of sheet material and an intervening and substantially `co-extensive vapor seal ply, together with a channel having a base portion tions extending from said base portion toward said mounting web and having 'marginal anges bonded to the inner sheet material ply of said mounting web', an insulating bat within said channel between the sides thereoha cover ply spanning said channel between said flanges, stitching through the cover ply oi--the bath and the base portion of said channel, and vaporseal means covering the stitching and bonding the cover ply to the inner sheet material piy of said mounting web. Y

15.-I'hermai insulation comprising an elongated 'oat of iibrous'insulating material having substantially parallel faces and sides converging toward one oi said faces, of a cover ply against the last mentioned face of said bat, a channel including a base and side portions embracing the other face and the sides of said bat, said channel including marginal ange portions projecting Alaterally from said cover ply, stitching through f the cover ply of the bat and thebase portion oiv the channel, a layer of adhesive vapor-sealing material spanning portions of said flanges said cover ply and said stitching, and a mounting web bonded by said material to said anges and said cover ply. 16. Thermal Vinsulation comprising the combination with an elongated bat having faces and sides, o enclosing means including wall portions disposed about said faces and sides, stitching extending through at least one of said wall portions and said hat and comprising means for positioning the material of saidl bat, a mounting web adhesively joined to said enclosure means and projecting laterally at each side of one of the faces oi said bat and including a vapor seal extending 'substantially unbroken across said face, and additional vapor sealing material covering and bonded to Said stitching.

17. Thermal insulation comprisingV an elongated bat of insulating material having opposing larger and smaller faces and sides converging toward the smaller face, a protective channel about the larger face and said converging sides and having lateral anges adjacent the smaller face of the bat, a cover ply abutting said smaller face,

stitching through the cover ply, the bat, and the' channel, and a mounting web bonded to said ilange and cover plyand provided with at least one layer of vapor sealing material substantially continuous across the hat.' and additional vapor sealing material over said stitching.

.of the hat, stitching through the walls at the bination with a mounting -web including a vapor seal ply, Va channel having a back portion approximately parallel to said mounting 'web and faces of the bat and through the intervening portion of the bat, vapor sealing adhesive material covering the stitching on both of said walls, and

sheet material covering said vapor sealing material and adhesively joined thereby to the respective last mentioned walls, the sheet material lyond the wall last mentioned and provided with V additional thickness of vapor sealing material substantially continuous across said bat 19. A device for the thermal insulation of buildings, comprising an insulating bat, a sheath of elongated form in which said bat is disposed, stitching extending through the sheath and the bat, vapor sealing means extending 'in ribbon form upon said sheath along said stitching, and a mounting web comprising a ply of foil bonded to said sheath by said vapor sealing means.

20. A device for the thermal insulation of buildings, comprising the combination with a relatively rigid mounting web, of a sheath having side wall portions connectedto said web and a back wall portion spaced from said web, and an insulating bat mounted within said sheath, the portion of said bat adjacent the back Wall portion of the sheath being materially Wider than the portion of the bat adjacent the mounting web and the portions of said bat and sheath remote from said web being laterally compressible independently or said web.

GRIFFITH E. EDWARDS.

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