AU2004287891B2

AU2004287891B2 - A material

Info

Publication number: AU2004287891B2
Application number: AU2004287891A
Authority: AU
Inventors: Vaughan Thomas
Original assignee: Individual
Current assignee: Individual
Priority date: 2004-10-29
Filing date: 2004-10-29
Publication date: 2010-12-16
Anticipated expiration: 2024-10-29
Also published as: AU2004287891A1

Description

- 1 A MATERIAL FIELD OF THE INVENTION 5 The present invention provides a material, methods of using the material and floor structures constructed using the material. In a first aspect, the invention material is an insulating material. In a second aspect, the invention material also provides an insulator. 10 BACKGROUND TO THE INVENTION In order to reduce construction costs there is a need for materials which can be installed efficiently. 15 Further, with increased concern about the sustainability of natural energy producing resources there has been an increased focus on the energy efficiency of buildings such as houses in order to reduce their energy 20 requirements. Whereas buildings built on concrete slabs have good thermal properties because the slab can absorb substantial amounts of heat, it is difficult to insulate 25 floors where floors are built on a frame structure. Accordingly, there is also a need for an alternative technique for insulating such floors and appropriate materials for doing so. 30 SUMMARY OF THE INVENTION In a first aspect, the invention provides a fire protection material comprising: a substrate formed of a fire rated material for 35 installation over a plurality of evenly spaced joists, the substrate having a plurality of attachment portions formed in said substrate and evenly spaced from one another, each 245i161_1 (GHMatters)29/10/2010 - 2 attachment portion being formed so that adhesive can pass through said substrate at the attachment portions so that in use flooring material can be adhered to the joists where the flooring material overlies the attachment 5 portions, the spacing of the attachment portions being greater than the spacing of the joists such that, in use, the fire rated material hangs below the top of the joists such that respective ones of a plurality of cavities are defined between the fire rated material and the flooring 10 material in the region between each neighbouring pair of the plurality of joists. In an embodiment, said attachment portions comprise porous sections of said substrate. 15 In an alternative embodiment, said attachment portions comprise perforations in said substrate. In an embodiment, said perforations are 20 apertures. In an embodiment, the fire protection material has insulation portions attached to the substrate. 25 In an embodiment, the insulating portions provide thermal and/or acoustic insulation. In an embodiment, said fire rated material is heat reflective. 30 In an embodiment, when the joist spacing is about 450mm, the attachment portion spacing is about 620mm. In an embodiment, when the joist spacing is about 35 600mm, the attachment portion spacing is about 770mm. In an embodiment, the fire protection material is 2451181_1 (GHMallers)29/1012010 -3 formed into a roll so that it can be rolled out across the joists during installation. In a second aspect, the invention provides a 5 method of fire protecting a floor comprising a flooring material supported on a plurality of evenly spaced joists, the method comprising: providing a substrate formed of a fire rated material having a plurality of attachment portions formed 10 in said substrate and evenly spaced from one another, the spacing of the attachment portions being greater than the spacing of the joists such that the fire rated material hangs below the top of the joists such that respective ones of a plurality of cavities are defined between the 15 fire rated material and the flooring material in the region between each neighbouring pair of the plurality of joists when the fire rated material is installed; locating said substrate with said attachment portions in register with said joists; 20 attaching said substrate to said joists such that said joists support said substrate and portions of said substrate extend between the joists; and adhering a flooring material to said joists where said attachment portions overlie said joists with adhesive 25 passing through said substrate at said attachment portions. In an embodiment, the method further comprises insulating the floor by providing thermal and/or acoustic 30 insulating material carried by the substrate. In an embodiment, the method further comprises fastening said flooring material to said joists with one or more fasteners. 35 The invention also provides a floor structure comprising: 2451181_1 (GHMatters)29/10/2010 - 4 a plurality of floor joists; a substrate formed of a fire rated material comprising a plurality of attachment portions formed in the substrate and evenly spaced from one another, said 5 substrate located with said attachment portions in register with said joists; and flooring material carried by the joists and adhered to said joists where said attachment regions overlie said joists by adhesive passing through said 10 substrate at said attachment portions, the spacing of the attachment portions being greater than the spacing of the joists such that the fire rated material hangs below the top of the joists such that respective ones of a plurality of cavities are defined between the fire rated material 15 and the flooring material in the region between each neighbouring pair of the plurality of joists. In an embodiment, the floor structure comprises an acoustic and/or thermal insulating material supported 20 by the substrate. In an embodiment, said fire rated material is heat reflective. 25 In an embodiment, when the joist spacing is about 450mm, the attachment portion spacing is about 620mm. In an embodiment, when the joist spacing is about 600mm, the attachment portion spacing is about 770mm. 30 BRIEF DESCRIPTION OF THE DRAWINGS A preferred embodiment of the invention will now be described in relation to the following drawings in 35 which: 2451161_1 (GHMattes)2911012010 - 4a Figure 1 is a cross-section of a floor structure built in accordance with the first preferred embodiment of the invention; 5 Figure 2 is a partial cut-away plan view of the insulating material of the present invention installed between a pair of joists; Figure 3 is a cross-structure of a floor 10 structure which shows the use of a fire rated material; and Figure 4 shows how two layers of fire rated material may be installed. 2451161_1 (GHMatters)29/10/2010 - 5 DESCRIPTION OF THE PREFERRED EMBODIMENT Figure 1 illustrates a floor structure which formed using a method of insulating a floor and a 5 insulation material of the first preferred embodiment. The floor structure comprises a plurality of bearers which will usually be supported on stumps (not shown) inserted into the ground. The bearer 1 illustrated 10 in Figure 1 is one of a plurality of bearers which all run in the same direction (see Figure 2). Supported on these bearers 1 are a plurality of joists 2 which run perpendicularly to the bearers 1. 15 In order to insulate the floor structure, an insulation material comprising a substrate in the form of a sheet of aluminium foil 5 and a plurality of insulation portions in the form of insulating batts 6 formed of fibre glass are overlaid on the joists such that they are 20 supported by the joists 2 with the insulating batts 6 below the intended level of the flooring material 3. The aluminium foil is fastened to the joists, typically by staples using a staple gun. The flooring material may be wooden floor boards, composite board, particle board or 25 the like. As shown in Figure 2, the insulation material has a plurality of apertures 7 through the material which are spaced apart in order to correspond to the spacing of the 30 joists 2. These apertures 7 provide attachment portions for allowing the flooring material 3 to be attached to the joists. That is the attachment portions permit attachment of the flooring and joists rather than acting to actively attach the substrate to the joists (the substrate can be 35 separately attached to the joists by fasteners, if desired). 802895_i (GHManers)28/10/2009 - 6 These apertures allow flooring 3 to be adhered to joists 2, thus preventing the floor from squeaking. Furthermore, the flooring 3 is also fastened to the joists 2 by fasteners such as nails. 5 It will thus be seen by referring to Figure 1 that the substrate 5 hangs below the top surface 4 in order to accommodate the insulating batts 6. Thus, persons skilled in the art will appreciate that the 10 additional length of aluminium foil 5 between the attachment portions which overlie the joists and one side of the batt 6 corresponds substantially to the height of the insulating batts. Typically, the joist spacing is 450mm in which case the length of aluminium foil from 15 attachment portion to attachment portion is about 620mm. Similarly, if the joist spacing is 600mm the length of aluminium foil is about 770mm. The insulation material of the preferred 20 embodiment will usually be supplied as a roll of material. As the spacing of joists is standard, one end of the roll can be aligned and then, the material can be deployed rapidly by rolling it out. 25 Persons skilled in the art will appreciate that there are a large number of alternative embodiments which fall within the scope of the invention. For example, while the invention has been 30 described in relation to a wooden structure for supporting flooring material, the invention is equally applicable to situations where the frame is metal. Similarly, while the spaced attachment portions 35 in the preferred embodiment are provided by a number of apertures, the attachment portions may be provided by many other type of perforations provided these allow adhesive 802895_1 (GHMatters)26/10/2009 - 7 to pass from one side of the material to another in order to allow the flooring to be adhered to the joists to prevent squeaking. Indeed, the substrate may be formed from a porous material or have porous portions where it is 5 designed to be attached to the joists. Further, while it is preferred that the substrate is a sheet of heat reflecting aluminium foil, it will appreciated that other substrates may be used while 10 obtaining some or all of the benefits of the present invention. For example, other heat reflecting materials will clearly be suitable. Further, where the substrate is merely required to support the insulating material it need not be formed of a heat reflecting material. It could be 15 for example, formed of plastic. In one particularly preferred embodiment, the substrate is formed of a fire rated material to thereby provide fire protection in addition to insulation. 20 The substrate may also be a web, for example a lattice-like web of strips of material and function to support the insulating portions. Further, while it is preferred that the insulating portions are supported against gravity by the substrate or web, the insulating 25 material can be supported by its attachment to the substrate or web and hang below the substrate or web in use. This is particularly suitable where the insulation material is to be installed between floors, as if the material becomes detached it will still be supported, for 30 example by the ceiling. In the preferred embodiment, the insulating portions are provided by fibre glass batts adhered to the aluminium foil. Persons skilled in the art will 35 appreciate that other insulating materials may also be used - e.g. polyester batts or rockwool. The insulating material may alternatively or additionally be chosen to 802895_1 (GHManters)26/1012009 - 8 provide acoustic insulation. Further, in embodiments where the invention is provided in the form of a insulation material, the 5 insulating material must be attached to the substrate in order to allow for ready installation. However, where the invention is embodied as a floor structure or as a method, the insulating material could be provided separately and installed separately to the substrate. Although, it is 10 preferred that it is provided with insulating material attached to the substrate. Further, while the example of fasteners used to attach the substrate to the joists and the flooring to the 15 joists are given above a person skilled in the art will appreciate the number of different fasteners can be used. For example, if a metal floor substrate is used, fasteners in the form of screws would be more appropriate than nails. Further, it may be possible to attach the 20 substrate to the joist using an adhesive rather than staples depending on the embodiment. In a further embodiment of the method of the invention, the substrate could be perforated after it has 25 been installed in order to match to the joists spacing. Persons skilled in the art will also appreciate that joists and bearers could run in different directions in different areas of the floor structure. 30 Referring to Figure 3 there is shown a second embodiment which relates to the second aspect of the invention. 35 As discussed above, the substrate can be a fire rated material in order to provide fire protection to the structure. Figure 3 illustrates that in accordance with 802595_1 (GHManers)28/10/2O9 - 9 the second aspect of the invention a substrate 15 formed of a fire rated material may be conveniently installed in the building with the substrate otherwise constructed in accordance with the substrate of the first embodiment 5 that is by providing attachment portions where an adhesive can pass through the substrate 15 in order to allow the flooring 3 to be attached to the joists 2. The material can then be rapidly deployed in the construction of a structure by rolling it out over the joist with the 10 attachment portions in register with the joists. The flooring material can then be deployed very quickly during construction of the structure. Figure 4 shows an alternative embodiment where 15 fire rated substrate 15 is located between a floor 3 and a ceiling material (not shown) where the floor 3 is between two different levels of a structure. The substrate 15 formed of fire rated material is attached to both the top and bottom of the deep floor joists of the floor structure 20 to provide fire protection between the two levels of the building. There may also be provided a thermal or acoustic insulating material carried by one or both of the substrates. 25 A person skilled in the art will appreciate that numerous other variations fall within the scope of the invention described herein. For example, where there is a danger of moisture build up on the substrate, drainage holes may be provided in the substrate to allow moisture 30 to pass therethrough. 8028951 (GHMatters)26V1012009

Claims

1. A fire protection material comprising: a substrate formed of a fire rated material for 5 installation over a plurality of evenly spaced joists, the substrate having a plurality of attachment portions formed in said substrate and evenly spaced from one another, each attachment portion being formed so that adhesive can pass through said substrate at the attachment portions so that 10 in use flooring material can be adhered to the joists where the flooring material overlies the attachment portions, the spacing of the attachment portions being greater than the spacing of the joists such that, in use, the fire rated material hangs below the top of the joists 15 such that respective ones of a plurality of cavities are defined between the fire rated material and the flooring material in the region between each neighbouring pair of the plurality of joists. 20

2. A fire protection material as claimed in claim 1, wherein said attachment portions comprise porous sections of said substrate.

3. A fire protection material as claimed in claim 1, 25 wherein said attachment portions comprise perforations in said substrate.

4. An fire protection material as claimed in claim 3, wherein said perforations are apertures. 30

5. A fire protection material as claimed in any one of claims 1 to 4 comprising insulation portions attached to the substrate. 35

6. A fire protection material as claimed in claim 5, wherein the insulating portions provide thermal and/or acoustic insulation. 2451161_1 (GHMatterS)29/10/2010 - 11

7. A fire protection material as claimed in any one of claims 1 to 6, wherein said fire rated material is heat reflective. 5

8. A fire protection material as claimed in any one of claims 1 to 7, wherein when the joist spacing is about 450mm, the attachment portion spacing is about 620mm. 10

9. A fire protection material as claimed in any one of claims 1 to 7, wherein when the joist spacing is about 600mm, the attachment portion spacing is about 770mm.

10. A fire protection material as claimed in any one 15 of claims 1 to 9, formed into a roll so that it can be rolled out across the joists during installation.

11. A method of fire protecting a floor comprising a flooring material supported on a plurality of evenly 20 spaced joists, the method comprising: providing a substrate formed of a fire rated material having a plurality of attachment portions formed in said substrate and evenly spaced from one another, the spacing of the attachment portions being greater than the 25 spacing of the joists such that the fire rated material hangs below the top of the joists such that respective ones of a plurality of cavities are defined between the fire rated material and the flooring material in the region between each neighbouring pair of the plurality of 30 joists when the fire rated material is installed; locating said substrate with said attachment portions in register with said joists; attaching said substrate to said joists such that said joists support said substrate and portions of said 35 substrate extend between the joists; and adhering a flooring material to said joists where said attachment portions overlie said joists with adhesive 2451181_1 (GHMatters)29/10/2010 - 12 passing through said substrate at said attachment portions.

12. A method as claimed in claim 11, further 5 comprising insulating the floor by providing thermal and/or acoustic insulating material carried by the substrate.

13. A method as claimed in claim 11 or claim 12, 10 further comprising fastening said flooring material to said joists with one or more fasteners.

14. A floor structure comprising: a plurality of floor joists; 15 a substrate formed of a fire rated material comprising a plurality of attachment portions formed in the substrate and evenly spaced from one another, said substrate located with said attachment portions in register with said joists; and 20 flooring material carried by the joists and adhered to said joists where said attachment regions overlie said joists by adhesive passing through said substrate at said attachment portions, the spacing of the attachment portions being greater than the spacing of the 25 joists such that the fire rated material hangs below the top of the joists such that respective ones of a plurality of cavities are defined between the fire rated material and the flooring material in the region between each neighbouring pair of the plurality of joists. 30

15. A floor structure as claimed in claim 14, comprising an acoustic and/or thermal insulating material supported by the substrate. 35

16. A floor structure as claimed in claim 14 or claim 15, wherein said fire rated material is heat reflective.

245111.1 (GHMatters)29110/2010 - 13

17. A floor structure as claimed in any one of claims 14 to 16, wherein the joist spacing is about 450mm and the attachment portion spacing is about 620mm. 5

18. A floor structure as claimed in any one of claims 14 to 16, wherein the joist spacing is about 600mm and the attachment portion spacing is about 770mm. 2451161_i (GHMatters)29/10/2010