AU2012201847A1 - Corrugated Insulation Layer - Google Patents

Abstract

Abstract 1. A corrugated nsuiation layer [fr use to insulate an underside of a roof struture of a building and including: a. a support layer extendable across load bearing surfaces of a roof suppod structure; b. an insulation material which is supportable by the support tayer; wherein the insulation material Fords in a corrugated manner to form the corrugated insulation layer. c'J CC\J oo0 C\J 0)0 CDt C\Jj

Description

Regulation 3.2 AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT APPLICANT: Fibrework Australia Pty Ltd INVENTION TITLE: Corrugated Insulation Layer The following statement is a full description of this invention, including the best method of performing it known to me: - -2 CORRUGATED INSULATION LAYER Field of the Invention The invention generally relates to an insulation layer and more particularly is concerned with a corrugated insulation layer. 5 Background to the Invention Insulation installed in buildings is important given the benefit which can be achieved in respect of the reduction of energy expenditure required to heat or cool the building. Energy required to heat or cool the building, normally in the form of electricity, can be expensive and often is produced by relying on carbon 10 fuels. It would therefore be desirable to increase the energy efficiency of the building and reduce the amount of heat energy absorbed from or discharged to the environment. Although heat diffusion can readily occur through walls structures of a building, often most heat diffusion occurs through a roof structure of the building. 15 During summer, a roof cavity can be heated to very high temperatures due to the exposure of an outer surface of the roof structure to the sun. Conversely, in winter the roof cavity can become quite cold due to the natural ventilation features of the roof structure. Accordingly, in summer the heat of the roof cavity is transferred into an interior of the building. Also, in winter, heat energy 20 used to warm the interior of the building is conducted into the roof cavity. It is therefore apparent that an effective insulation layer positioned in between the roof cavity and the interior of the building or in the roof cavity would reduce the amount of heat being transferred through the roof of the building. Insulation layers generally are formed using a fibrous material. However, 25 depending on the application of the insulation layer, it can happen that the insulation layer is squashed thereby reducing the efficacy of the insulation layer to retard the transfer of heat across the insulation layer. This could result in large areas of the insulation layer adopting a squashed configuration. Clearly this will be undesirable.

-3 Accordingly, it is an object of the present invention to overcome or ameliorate at least one or more of the disadvantages of the prior art or to at least provide a useful alternative. Summary of the Invention 5 The invention generally provides for a corrugated insulation layer for use to insulate an underside of a roof structure of a building and which includes an integral support layer extending across load bearing surfaces of a support structure of the roof structure and an insulation material which is supported by the support layer; wherein the corrugated insulation layer is shaped to define a 10 number of air pockets above the insulation material thereby to improve insulation characteristics of the insulation layer. In one embodiment, the insulation material may have a corrugated profile, when viewing a longitudinal cross-section of the material, and may be supported on an underside thereof thereby to hold the material in the 15 corrugated profile. A support layer may support the corrugated insulation material on the underside thereof. The support layer may be in the form of a sheet of material which is secured to the underside of the corrugated insulation material thereby to substantially lock 20 in the corrugated profile of the insulation material and to provide support to the corrugated layer when extending over spaced apart purlins of the roof support structure. In a different embodiment, the support layer may extend over the spaced apart purlins; wherein the support layer is formed to have a corrugated profile 25 thereby to cause the supported insulation material to have a corrugated profile when extending longitudinally over the plurality of spaced apart purlins. The support layer may be in the form of a mesh material.

-4 In a further embodiment of the invention, the invention relates to a corrugated insulation layer for use with a roof structure having a purlin layer formed by a plurality of spaced apart purlins; the corrugated insulation layer includes an insulation material and a support layer which underlies the insulation material; 5 the support layer is formed to have a corrugated profile when extending longitudinally over the spaced apart purlins thereby to cause the supported insulation material to have a corrugated profile when extending longitudinally across the purlins thereby to define a number of air pockets above the corrugated insulation material in between each the pair of adjacent purlins of 10 the plurality of purlins. The support layer may be secured at one end to a purlin position at one end of the plurality of purlins; wherein the support layer is bent over the purlins thereby to form in the support layer a plurality of intermediate portions each of which is positioned in between a pair of adjacent purlins; wherein each of the 15 intermediate portions extends into the purlin layer so that the intermediate portions are spaced apart from load bearing surfaces of the purlin layer; and wherein the positioning of the intermediate portions relative to the load bearing surfaces causes the insulation material to have a corrugated profile when the insulation material longitudinally extends across the purlin layer. 20 The support layer may be shaped to have a purlin engaging formation for each of the plurality of purlins thereby allowing the support layer to be meshed with the purlin layer by registering each purlin engaging formation with a respective purlin. Each of the purlin engaging formations may be shaped to reduce a width of a 25 section of the purlin engaging formation which extends substantially parallel with a respective load bearing surface of the respective purlin; wherein the width of the section reduces the amount of insulation material which is compressed by an outer portion of the roof structure which rests on the load bearing surfaces.

-5 Each of the intermediate portions may be shaped thereby to include first and second section each of which extends from an adjacent purlin engaging formation with an acute angle relative to the respective load bearing surface; wherein the angular positioning of the respective first and second sections 5 allows the insulation material Each of the plurality of purlins may have a substantially rectangular cross section profile; wherein each of the purlin engaging formations is shaped to substantially match the cross-sectional profile of the purlins. The purlin engaging formations may be formed at predetermined positions 10 along a length of the support layer so that the spacing of the purlin engaging formations match the spacing of the plurality of purlins thereby allowing the support layer to be shaped before being positioned on top of the purlin layer. The invention, in a further embodiment, also extends to a method of forming an insulation layer for use with a roof structure having a supporting purlin layer 15 which is formed by a plurality of purlins; the method including the steps of: forming a support layer of the insulation layer to have a corrugated profile which extends across the purlin layer; and covering the support layer with an insulation material so that in support the corrugated support layer causes corrugations in the insulation material 20 thereby forming a plurality of air pockets above the insulation material between each pair of adjacent purlins. The invention also extends, in another embodiment, to a method of forming an insulation layer to provide insulation underneath a roof structure having a purlin layer consisting of a number of spaced apart purlins; the method including the 25 steps of: forming a support layer of the insulation layer to have a purlin engaging formation at predetermined positions in the support layer and to have an intermediate portion between each pair of adjacent purlin engaging formations thereby allowing the support layer to meshed with the purlin layer by engaging -6 a purlin engaging formation with a purlin so that each purlin intermediate portion extends into the purlin layer; covering the support layer with an insulation material thereby causing in support the insulation layer to adopt a corrugated profile when extending 5 longitudinally across the purlin layer thereby forming, between each pair of adjacent purlins, an air pocket which improves the insulation characteristics of the insulation layer. In a further embodiment, the invention provides a corrugated insulation layer having at least two layers one of which is substantially continuous and the 10 other of which is substantially corrugated to provide structure to the insulation layer and to form a plurality of air pockets or cavities inside the insulation layer. The at least two layers may be substantially adjacent each other. The at least two layers may be formed from an integral piece of material. One of the at least two layers may be folded to form the other of the at least 15 two layers. In one embodiment, the invention extends to a corrugated insulation layer which includes a body of fibrous insulation material which contains a lining at least on a first side of the body; wherein the body includes a corrugated first layer and an adjacent second layer which extends substantially continuous 20 along the first layer; wherein the first layer includes a plurality of ridges which define a plurality of cavities in between pairs of adjacent ridges; and wherein the ridges form a support structure for supporting the lining on the first side relative to the second layer. The first and second layers may be manufactured from an integral piece of 25 fibrous material. The integral piece of fibrous material may be folded in order to form the ridges of the first layer and to form the second layer. The plurality of ridges may be formed at regular intervals.

-7 Each cavity of the plurality cavities may extend into the body from the first side. The lining may be used to cover the cavities of the first layer thereby to seal the cavities from atmosphere. The body may have a thickness which is in the order of between 50 mm and 5 150 mm; and wherein each cavity has a cross-sectional diameter which between 50% and 80% of the thickness of the body. The body may have a thickness which is around 95 mm and each cavity may have a cross-sectional diameter which is around 66% of the thickness of the body. The folding of the fibrous material may allow at least the first layer to be io configured to allow one or more ridges to be collapsed while maintaining the structural integrity of adjacent ridges. Each cavity may be in the form of a groove which extends across a width of the body. The first layer may have a thickness which is substantially half of a thickness of 15 the second layer; and wherein the thickness of the second layer is between 70% and 80% of the thickness of the body. The thickness of the layer may be around 75% of the thickness of the body. The thickness of the first layer may be around 20 mm and the thickness of the second layer may be around 65 mm. 20 The lining may be glued to the first layer. In another embodiment, the invention extends to a corrugated insulation layer which includes a body of fibrous insulation material which contains a lining on first and second sides of the body; wherein the body comprises of a first layer and an adjacent second layer which extends substantially continuous along the 25 first layer; wherein the first layer is formed using material of the second layer and includes a plurality of ridges which define a plurality of cavities in between pairs of adjacent ridges of the plurality of ridges; and wherein the ridges form a -8 support structure for supporting the lining on the first side of the body relative to the second layer thereby allowing the lining to cover the plurality of cavities. The invention, in a further embodiment, also extends to a method of forming an insulation layer which includes the steps of: 5 forming, in a fibrous sheet body, a first layer and a second layer which extends substantially continuous adjacent the first layer; and forming the first layer to include a plurality of ridges thereby to define a cavity between each pair of adjacent ridges of the plurality of ridges and thereby to provide support to a lining which extends across an outer side of the 10 body and which covers the cavities. The first layer may be folded to form the plurality of ridges. The first and second layers may be formed from an integral piece of material and wherein folding of the material causes the first layer to include a plurality of ridges and causes the second layer to be formed adjacent the first layer and to 15 extend substantially continuous adjacent the first layer. The invention also extends, in another embodiment, to a method of forming an insulation layer which includes the steps of: forming a plurality of folds in an integral piece of fibrous material to form a fold profile in a fibrous body which causes the body to have a first layer which 20 is substantially corrugated through a plurality of ridges formed by the plurality of folds and a second layer which extends substantially continuous adjacent the first layer; securing the plurality of folds relative to each other thereby to maintain the fold profile of the fibrous body; and 25 covering a first side of the fibrous body thereby covering cavities formed between adjacent pairs of ridges of the plurality of ridges. The fibrous body may be lined at opposed first and second sides thereof thereby to secure the plurality of folds relative to each other and to cover the plurality of cavities.

-9 The fold profile may allow the body to be configured so that one or more ridges of the plurality of ridges are capable of being collapsed while maintaining structural integrity of adjacent ridges. The lining may be attached to the second layer thereby to secure the fold 5 profile of the fibrous body using the lining of the second side. The plurality of ridges may provide a support structure thereby to support the lining of the first end of the fibrous body. In a further embodiment of the invention, the invention relates to a support layer for use in a corrugated insulation layer having an insulation material and io used with a roof structure having a support structure; the support layer includes a body of sheet material which is formed to have a corrugated profile when extending longitudinally over the support structure thereby to cause the supported insulation material to have a corrugated profile when extending longitudinally across the purlins thereby to define a number of air pockets 15 above the corrugated insulation material in between each the pair of adjacent purlins of the plurality of purlins. Brief Description of the Drawings In order that the invention can be more readily understood one or more examples of the invention are described with reference to the accompanying 20 drawings wherein: Figure 1 is a side schematic representation of a corrugated insulation layer according to a first embodiment using the principles of the invention; Figure 2 is a side schematic representation of a corrugated insulation layer according to the invention; 25 Figure 3 is a side view showing a schematic representation of the corrugated insulation layer of figure 2 in use over a purlin layer of a roof support structure; Figure 4 is a side schematic representation of a manufacturing device used to manufacture the corrugated insulation layer of Figure 2; -10 Figure 5 is a side view showing on an enlarged scale part A, of the manufacturing device showing Figure 4, in use; Figure 6 is a view similar to Figure 5 showing features required on a forming assembly in order for part A to form the corrugated fibrous insulation 5 layer; Figure 7 is a perspective photographic view of a different embodiment of the corrugated insulation layer according to the principles of the invention; Figure 8 is a perspective photographic view of a support layer used in the corrugated insulation layer of Figure 7; 10 Figure 9 is a perspective photographic view of a device used to form a corrugation in the support layer of Figure 8; Figure 10 is an end view showing a schematic representation of the Figure 9 device in use and having partially formed a purlin engaging formation of the support layer; 15 Figure 11 is a view similar to Figure 10 showing the device of Figure 9 having completed the step of forming the purlin engaging formation. Figure 12 is a side view of a schematic representation showing a variation of the device used to form corrugations in the support layer of Figure 8. 20 Figure 13 is a side view of a schematic representation showing the support layer of Figure 7 having a different corrugated shape Figure 14 is a perspective photographic view of a further different embodiment of the corrugated insulation layer according to the principles of the invention having a substantially square ; 25 Description of Illustrated Embodiments of the Invention Referring to the company representations, Figure 1 illustrates with a schematic representation a corrugated insulation layer 2 for use to insulate an underside of a roof structure 4 of a building. The roof includes a roof support structure or purlin layer 6 which is formed from a plurality of spaced apart purlins 8. It 30 should be noted, although the support structure is shown in the illustrated examples as being a purlin layer, that the principles of the invention can - 11 equally be used on other types of roof support structures such as roof trusses or the like. The invention is therefore not limited in this regard. The corrugated insulation layer 2 includes an insulation material 10 and is shaped to define a number of air cavities or pockets 12 above the insulation 5 material thereby to improve insulation characteristics of the insulation layer. One embodiment of the corrugated insulation layer 2 is shown in Figures 2 and 3. Another embodiment 200 of the corrugated insulation layer is shown in Figure 7. The corrugated insulation layer 2 includes a number of small air pockets 12 above the insulation material whereas the corrugated insulation 1o layer 200 includes one air pocket formed between each pair of adjacent purlins 8. The corrugated insulation layer 2 will first be described in greater detail with reference to Figures 2 to 6 whereafter the corrugated insulation layer 200 will be described in greater detail with reference to Figure 7 to 12. In Figure 1 the insulation material is also depicted in dotted outline which 15 extends in between pairs of adjacent purlins. This aspect of the invention is covered by the corrugated insulation layer 200 in which the insulation material has a substantially corrugated profile. Referring to Figures 2 and 3, in the corrugated insulation layer 2 the insulation material 8 is in the form of a body of fibrous material which has a first layer 14 20 and a second layer 16. The first layer is formed to have a substantial corrugated profile 18 and the second layer is formed to extend substantially continuous adjacent the first layer. The body is covered with a lining 20 on the first and second sides 22 and 24 of the body. The corrugated profile 18 of the first layer 14 is formed through a plurality of 25 ridges 28. Each pair of adjacent ridges 30 defines a cavity 32 which extends into the body 10 from the first side 22. Thus, the first layer 14 is formed with a plurality of cavities which are defined between adjacent pairs of ridges 30. The plurality of ridges 28 forms a support structure 34 which supports the lining 20 on the first side 22 of the body 12 relative to the second layer 16. The -12 support structure allows the lining 20 to cover the cavities 32 in a manner in which the cavities are substantially sealed from atmosphere through the lining 20. The body 12 is formed from an integral piece of fibrous material such as glass 5 fibre, Rockwool, natural wool, polyester, polystyrene, fibres, foam, bubble wrap or the like. The integral piece of fibrous material is folded thereby to form the corrugated first layer 14 as well as the substantially continuous second layer 16. An example of a machine 38 which can be used to construct the corrugated insulation layer 10 is shown in Figure 4. However, it should be 10 noted that the machine 38 can have different constructions, configurations and mechanisms in order to implement the principles of the present invention in a corrugated insulation layer without departing from the spirit and scope of the invention. The machine 38 includes a roll of fibrous insulation material 40 and two rolls of 15 lining or foil 20 (hereinafter referred to as foil A and foil B). The machine comprises of a frame 42, which supports two glue applicators 44 one for each of the foils A and B, a drying oven 46, and a forming assembly 48 which includes a main forming drum 50 and a spigot track assembly 52. The forming assembly 48 is adapted to receive in a controlled manner foil from 20 the glue applicators 44 and insulation material from the drying oven 46. Insulation material, drawn from the roll of fibrous insulation material 40, is dried in the drying oven 46 before being fed, using a roller mechanism 54 in between the spigot track assembly 52 and the main forming drum 50. Referring in addition to Figure 5, the spigot track assembly includes a plurality 25 of spigots 56 which are mounted to an endless chain 58. A number of sprockets 60 are used to import linear movement to the endless chain 58 as well as to provide tension thereto. The main forming drum 50 includes a number of sockets 62 which extends into the main forming drum 50 from an outer edge 64 of the drum 50. As best can -13 be seen in Figure 6, a sidewall 66 between adjacent sockets carries a cap 68 of which each respective free end 70 extends into one of the adjacent sockets. The cap 68 includes suction holes 72 which are positioned substantially on each free end 70 so that the suction holes are directed towards an interior 74 5 of a respective socket 62. It should be noted that, although in Figure 6 only some of the caps 68 are shown to have suction holes to simplify the drawing, it should be understood that each one of the caps 68 contains the suction holes 72. Returning to Figure 5, material 76 sourced from the roll of fibrous insulation 10 material 40, once dried, is fed through part of the roller mechanism 54 in between the spigot track assembly 52 and the main forming drum 50. The movement of the endless chain 58 is synchronised with the rotational movement of the drum 50 about a central axis 80 (see Figure 4). This allows linear movement of the endless chain 58 to insert a spigot 56 into a respective 15 socket 62. The respective spigot 56 is maintained inserted into the respective socket 62 until sufficient linear movement in the endless chain and rotational movement of the main forming drum 50 causes the respective spigot to be pulled from the respective socket. In the illustrated example shown in Figure 5, the main forming drum 50 is 20 caused to rotate in an anticlockwise direction 82 about the central axis 80. The sprockets 60 cause the endless chain 58 to rotate clockwise relative to the main forming drum 50. Also, the material 76 is fed from a right-hand side 84. As the material 76 moves in between the spigot track assembly 52 and the main forming drum 50, the spigot 56 forces a portion 86 of the material 76 into 25 the interior 74 of a respective socket 62. A feeding speed, with which the part of the roller mechanism 54 feeds the material 76, is adjusted to allow for a portion 86 of the material 76 to be pushed substantially into the respective socket as opposed to being stretched into the respective socket. This allows for the structural integrity of the material to be substantially maintained. The 30 portion 86 is being kept into position, i.e. being inserted into a respective socket 62, through suction generated through the suction holes 72 of a - 14 respective adjacent cap 68. This allows insertion of a respective portion 86 into a respective socket 62 to be maintained once the respective spigot 56 is withdrawn from the respective socket. A section 88 of foil A 20 is then secured to the second side 24 of the body of 5 fibrous material 10. The glue applicators 44 causes glue to be applied to an appropriate side of the section 88 thereby to allow the section 88 to be secured to the second side through the glue. Thus, the body 10 is caused to have a fold profile 92 (referring additionally to Figure 1) by processing the material 76 with the spigot track assembly 52 and the main forming drum 50. This profile 10 is substantially maintained, at least on the second side 24 of the body 10, through the application of the foil A lining 20 to the second side 24 of the body. As best can be seen Figure 4, the partially lined body 10, i.e. only contains a lining 20 on the second side 24, is rotated about the central axis 80. The engagement of the partially lined body 10 with the main forming drum 50 is 15 promoted through the suction holes 72 of the caps 68. At an appropriate position the partially lined body 12 is detached from the main forming drum 50 so that the first side 22 can be covered with a section 94 of foil B 20. As with the section 88, the glue applicators 44 causes glue to be applied to an appropriate side of the section 94. This allows application of the section 94 to 20 the first side 22 of the body 12 to secure the section 94 to the body 10. Thus, the section 94 covers the cavities 32. The corrugated insulation layer 2 is now formed and is further described in greater detail referring to Figures 2 and 3. The fold profile 92 of the body 10 includes a number of folds 96 which coincide 25 with a respective ridge of the plurality of ridges 28. A fold 96 is formed where a spigot 56 pushes the portion 86 of the material 76 into the respective socket 62. Due to the nature of the fold profile 92, i.e. forming a number of folds 96 in a substantially integral piece of material, part of the body 10 can be collapsed while maintaining, at least to some extent, the fold profile of adjacent sections 30 of the body. The lining of the body at the second side 24 maintains base ends - 15 98 of each folded section 100 adjacent each other. The base ends 98 form the second layer 16. Thus, alignment of the base ends 98 relative to each other is therefore required in order to construct the second layer. Each folded section 100 further includes two ridge portions 102 each of which 5 extends from one end of the base end 98. Thus, two ridge portions 102 form one ridge 28. As mentioned hereinabove, the plurality of ridges 28 form a support structure 34 which support the lining 20 on the first side 22 of the body 10. Referring in particular to Figure 2, the modular construction, i.e. forming the first and second layers 14 and 16 using a plurality of folded sections 100, 10 allows for a section 106 of the body to be deformed without impacting substantially on adjacent folded sections 100. This allows for the corrugated insulation layer 10 to be secured to a purlin 8 without impacting substantially on adjacent sections of the corrugated insulation layer. Furthermore, the use of the linings 20 maintains substantially the fold profile 92 of the body 12. 15 Referring back to Figure 2, the body 12 has a height 112 which is around 95mm. The first layer has a thickness 114 which is around 30mm and the second layer has a thickness 116 which is around 65mm. Thus, the second layer has a thickness which is substantially twice the thickness of the first layer. Each folded section 100 has a length 118 which is around 100mm. Each 20 cavity 32 has a radius 120 which is around 65mm. Each ridge 28 has a thickness 122 which is around 35mm. The cavities 32 allow the body 12 to have a layer which contains a plurality of air pockets 10. Since air is a poor conductor of heat, the inclusion of the air pockets 10 into the body 12 improves the insulation characteristics of the 25 corrugated insulation layer 12. However, the thickness 114 of the first layer 14 is such so that the likelihood is reduced of a convection current being established inside each cavity 32. Such a current has the possibility of transmitting heat across the cavities thereby reducing the insulation efficacy of the air pockets.

-16 The support structure 34 promotes the retention of the fold profile 92 of the body 10. Furthermore, the lining of the body 10 with the foils A and B further assists in maintaining the fold profile 92. It is therefore possible to suspend the corrugated insulation layer 2 between adjacent purlins 8 without substantially 5 impacting negatively on the insulation characteristics of the corrugated insulation layer 2. In the corrugated insulation layer 2 the foil A 20 forms a support layer 124 which supports the body 10 on the second or underside 24. The support layer assists in the suspension of the corrugated insulation layer from the purlins 8. 10 The apparatus 38 is adapted to process rolls of fibrous insulation materials 40 and foils 20. Accordingly, each cavity 32 will be in the form of a groove which extends substantially across a width 126 of the body 12. Furthermore, as is particularly evident in Figure 2, the mounting of the corrugated insulation layer 2 to a purlin 8, although reducing the height 112 of 15 the section 106, the fold profile 92 promotes the formation of air pockets 10 around the purlin. Such air pockets should increase the insulation characteristics of the corrugated insulation layer around the purlin. As mentioned hereinabove, a second embodiment 200 of the corrugated insulation layer is shown in Figure 7. Like reference numerals are used to 20 designate like components between the corrugated insulation layers 2 and 200. The corrugated insulation layer 200 includes an insulation material 10 which is in the form of a body of fibrous material. The corrugated insulation layer 200 extends across and above a purlin layer 6 of a roof 4 and is supported through 25 a support layer 124 which is in the form of a mesh material. The support layer 124 allows the insulation material to extend across the purlin layer in a corrugated manner. Figure 8 shows the support layer 124 in greater detail. The insulation material 10 and other components of the roof have been removed to simplify the figure.

-17 The support layer is shaped to extend in a close fitting manner across each purlin 8. The shaping is achieved by bending in the support layer a plurality of purlin engaging formation 202 at predetermined positions along a length of the mesh material. This allows the support layer to be meshed with the purlin layer 5 with each purlin engaging formation registered with a respective purlin. The support layer 124 further includes an intermediate portion 204 which is positioned in between a pair of adjacent purlin engaging formations 202. The bending of the wire mesh to form the purlin receiving formations causes the intermediate portions to extend into the purlin layer so that the intermediate io portions are spaced apart from load bearing surfaces 206 of the purlin layer. In use the load bearing surfaces typically support the outer portion of the roof structure for, for example the sheeting or tiling thereof. The positioning of the intermediate portions in between a pair of adjacent purlins causes the support layer to have a corrugated profile. 15 Figures 9 to 11 illustrate one type of apparatus 210 which can be used to form the purlin engaging formations 202 in the support layer 124. Figure 12 illustrates another type of apparatus 212 which can be used to form the purlin engaging formations. The apparatus 210 uses the purlins 8 as a base around which to bend the 20 support layer, in the form of a safety mesh, 124 thereby to form one purlin engaging formation 202 through the apparatus 210. Typically the apparatus 210 will be used in pairs thereby allowing the bending of the safety mesh not to cause an earlier formed purlin engaging formation to be stretched or straightened at least partly when a new purlin engaging formation is created. 25 The apparatus 210 includes a locking or hook bracket 214 at each end with which the apparatus is anchored, at least for vertical movement, relative to a respective purlin 8. The apparatus includes a pair of movable clamp arms 216 which are moved independently down from an open configuration 218, shown in Figure 10, to a clamped configuration 220 which is shown Figure 11. A pair - 18 of pivot arms 222 is used to move the clamp arms between the open and clamped configurations. The hook bracket 214 is part of a clamp assembly 224 which clamps onto the purlin to lock the anchored apparatus 210 to the purlin. The clamp assembly 5 includes a lever 226 which causes rotational movement of a clamp bracket 228 to and from a lock position 230 which is shown in Figure 11. Each of the pivot arms 222 moves adjacent to a notched plate 232. The notched plate includes a recess formation which allows the pivot arm to be locked in a predetermined position thereby to maintain the pivot arms in a 10 selected position. This reduces the likelihood of the clamp arms 216 from inadvertently moving between the open or clamped configurations 218 and 220. A safety strip 234 (see Figure 8) is used to secure one end of the safety mesh to an outer most purlin. Additionally, depending on requirement such as 15 Government Regulations, a safety strip can be used to secure a purlin engaging formation 202 at regular intervals to a respective purlin, for example every second purlin. The use of the safety strip 234 will reduce the likelihood of the support layer moving relative to the purlin layer, for example when a person stands on the support layer. 20 Figure 12 shows the apparatus 212 which can be also used to bend the support layer 124 to have a corrugated profile. Although it is possible to use the apparatus 210 during in situ installation of the corrugated insulation layer 200, the apparatus 212 will be positioned at one end of the purlin layer 6 thereby allowing the processed support layer to be drawn from the apparatus 25 212 and over the purlin layer 6 for meshing therewith. The apparatus includes a wire role from which mesh material is drawn to form the support layer 124. The apparatus includes a first pair of rams D and E with which the wire mesh is clamped for further processing. A second pair of rams A and B is used to form a purlin engaging formation 202 in the wire mesh -19 material. A ram C is used to draw a sufficient amount of wire mesh past the second pair of rams A and B. This is achieved by the ram C pushing towards the position marked N thereby drawing more wire mesh from the roll. The additional material allows the purlin engaging formation to be bent into the wire 5 mesh as opposed to being caused by stretching of the wire mesh material due to the clamping of the wire mesh by the first pair of rams D and E. Once the purlin engaging formation is formed using rams A and B, the material is moved along the apparatus using rollers H and F until the purlin engaging formation is positioned in between the rams D and E. Actuating of these rams causes a 10 clamping channel to be fitted over the purlin engaging formation thereby to clamp the wire mesh in between these two rams for further processing. This process is repeated until a sufficient length of wire mesh has been processed to fit across the purlin layer 6. The spacing in between the first and second pairs of rams can be adjusted 15 according to requirement thereby allowing the purlin engaging formations 202 to be spaced apart by a distance which matches the spacing in between adjacent purlins 8. The corrugated mesh material 124 allows the insulation material 10 to be draped over the purlin layer 6 thereby to form between each pair of adjacent 20 purlins an air pocket 12 above the insulation material. The recessing of the intermediate portions 204 into the purlin layer causes the insulation material to adopt a corrugated profile when the insulation material longitudinally extends across the purlin layer. Referring to Figure 13, each of the purlin engaging formations may be shaped 25 to reduce a width 236 of a section 238 of the purlin engaging formation 202 which extends substantially parallel with a respective load bearing surface 206 of the respective purlin 8. The reduction of the width of the section reduces the amount of insulation material which is compressed by an outer portion 240 of the roof structure which rests on the load bearing surfaces, for example the 30 roof sheeting. In the illustrated example the intermediate section 204 has a V shape. Each side of the V-shaped intermediate section 4 is relatively quickly - 20 away from the outer portion thereby reducing the amount of insulation material which is forced against the outer portion. The invention provides a corrugated -insulation layer of which the insulation material has a corrugated profile thereby to provide one or more air pocket or 5 cavities above the insulation material. The inclusion of the air pocket or cavities above the insulation material improves the insulation characteristics of the insulation layer. The invention also provides a corrugated insulation layer which includes two layers, one of which is substantially continuous and the other of which has a 10 substantial corrugated profile to form a plurality of air pockets inside the corrugated insulation layer. The corrugated profile also provides a support structure which assists in the supporting of a lining, relative to the substantially continuous layer, which is used to cover the air pockets. The corrugated insulation layer includes a number of folded sections which allows part of the 15 corrugated insulation layer to be secured to a support structure such as a purlin without substantially impacting negatively on the insulation characteristics of adjacent sections of the corrugated insulation layer. The invention further provides a corrugated insulation layer of which a support layer is corrugated thereby causing a supported insulation material to have a 20 corrugated profile thereby forming an air pocket above the insulation material which improves the insulation characteristics of the insulation layer. While we have described herein a particular embodiment of a corrugated insulation layer, it is further envisaged that other embodiments of the invention could exhibit any number and combination of any one of the features 25 previously described. However, it is to be understood that any variations and modifications which can be made without departing from the spirit and scope thereof are included within the scope of this invention as defined in the following claims.

Claims (53)

1. A corrugated insulation layer for use to insulate an underside of a roof structure of a building and including: a. a support layer extendable across load bearing surfaces of a roof 5 support structure; b. an insulation material which is supportable by the support layer; wherein the insulation material folds in a corrugated manner to form the corrugated insulation layer, and wherein the corrugated insulation layer is shaped to define a 10 number of air pockets between adjacent corrugations of the insulation material thereby to improve insulation characteristics of the insulation layer.

2. A corrugated insulation layer according to claim 1 wherein the insulation material forms a single corrugation between spaced roof support 15 structures.

3. A corrugated insulation layer according to claim 1 wherein the insulation material forms a plurality of corrugations between spaced roof support structures.

4. A corrugated insulation layer according to claim 1 or 2 wherein the 20 insulation material is supported on an underside thereof by the support layer thereby to hold the material in a corrugated profile.

5. A corrugated insulation layer according to claim 4 wherein the support layer includes a sheet material which is secured to the underside of the corrugated insulation material thereby to substantially lock in a 25 corrugated profile of the insulation material.

6. A corrugated insulation layer according to claim 4 or 5 wherein the support layer includes a sheet material which is secured to the -22 upperside of the corrugated insulation material thereby to substantially lock in a corrugated profile of the insulation material.

7. A corrugated insulation layer according to claim 4, 5 or 6 wherein the support layer includes a foil sheet material which is secured to the 5 underside and/or upperside of the corrugated insulation material thereby to substantially lock in a corrugated profile of the insulation material.

8. A corrugated insulation layer according to any one of the preceding claims wherein the support layer provides support to the corrugated layer when extending over spaced apart portions of the roof support 10 structure.

9. A corrugated insulation layer according to any one of the preceding claims wherein the load bearing surfaces of a roof support structure are spaced apart purlins and the support layer extends over the spaced apart purlins; wherein the support layer is formed to have a corrugated 15 profile thereby to cause the supported insulation material to have a corrugated profile when extending longitudinally over the plurality of spaced apart purlins.

10.A corrugated insulation layer according to any one of the preceding claims wherein the support layer includes a mesh material. 20

11. A corrugated insulation layer according to claim 10 wherein the mesh material of the support layer is preformed into a corrugated form that matches a single corrugation between spaced roof support structures with peaks fitting over adjacent spaced roof support structures.

12. A corrugated insulation layer according to claim 10 or 11 wherein the 25 mesh material of the support layer is preformed into a corrugated form that matches a plurality of corrugations between spaced roof support structures with peaks fitting over adjacent spaced roof support structures and peaks in between. - 23

13.A corrugated insulation layer according to any one of the preceding claims wherein the insulation material forms a plurality of corrugations between spaced roof support structures and substantially below the top surface of the spaced roof support structures wherein the number of air 5 pockets are substantially within the depth of the spaced roof support structures.

14.A corrugated insulation layer according to any one of the preceding claims wherein the spaced roof support structures has a purlin layer formed by a plurality of spaced apart purlins; the corrugated insulation 10 layer includes an insulation material and a support layer which underlies the insulation material; the support layer is formed to have a corrugated profile when extending longitudinally over the spaced apart purlins thereby to cause the supported insulation material to have a corrugated profile when extending longitudinally across the purlins thereby to define 15 a number of air pockets above the corrugated insulation material in between each the pair of adjacent purlins of the plurality of purlins.

15.A corrugated insulation layer according to any one of the preceding claims wherein the support layer is secured at one end to a purlin position at one end of the plurality of purlins; wherein the support layer is 20 bent over the purlins thereby to form in the support layer a plurality of intermediate portions each of which is positioned in between a pair of adjacent purlins; wherein each of the intermediate portions extends into the purlin layer so that the intermediate portions are spaced apart from load bearing surfaces of the purlin layer; and wherein the positioning of 25 the intermediate portions relative to the load bearing surfaces causes the insulation material to have a corrugated profile when the insulation material longitudinally extends across the purlin layer.

16.A corrugated insulation layer according to any one of the preceding claims wherein the support layer is shaped to have a purlin engaging 30 formation for each of the plurality of purlins forming roof support structure thereby allowing the support layer to be meshed with the purlin - 24 layer by registering each purlin engaging formation with a respective purlin.

17.A corrugated insulation layer according to claim 16 wherein each of the purlin engaging formations is shaped to reduce a width of a section of 5 the purlin engaging formation which extends substantially parallel with a respective load bearing surface of the respective purlin; wherein the width of the section reduces the amount of insulation material which is compressed by an outer portion of the roof structure which rests on the load bearing surfaces. 10

18.A corrugated insulation layer according to claim 16 Or 17 wherein each of the intermediate portions is shaped thereby to include first and second section each of which extends from an adjacent purlin engaging formation with an acute angle relative to the respective load bearing surface; wherein the angular positioning of the respective first and 15 second sections allows the insulation material.

19.A corrugated insulation layer according to claim 16, 17 or 18 wherein each of the plurality of purlins has a substantially rectangular cross sectional profile; and wherein each of the purlin engaging formations is shaped to substantially closely circumference the cross-sectional profile 20 of the purlins.

20.A corrugated insulation layer according to claim 19 wherein the purlin engaging formations are formed at predetermined positions along a length of the support layer so that the spacing of the purlin engaging formations match the spacing of the plurality of purlins thereby allowing 25 the support layer to be shaped before being positioned on top of the purlin layer.

21.A method of forming an insulation layer for use with a roof structure having a load bearing surfaces of a roof support structure of spaced apart plurality of purlins; the method including the steps of: -25 a. forming a support layer of the insulation layer to provide a corrugated profile which extends across the purlin layer; and b. covering the support layer with an insulation material so that in support the corrugated support layer causes corrugations in the 5 insulation material thereby forming a plurality of air pockets above the insulation material between each pair of adjacent purlins.

22. A method of forming an insulation layer to provide insulation underneath a roof structure having a purlin layer consisting of a number of spaced apart purlins; the method including the steps of: 10 a. forming a support layer of the insulation layer to have a purlin engaging formation at predetermined positions in the support layer and to have an intermediate portion between each pair of adjacent purlin engaging formations thereby allowing the support layer to meshed with the purlin layer by engaging a purlin 15 engaging formation with a purlin so that each purlin intermediate portion extends into the purlin layer; b. covering the support layer with an insulation material thereby causing in support the insulation layer to adopt a corrugated profile when extending longitudinally across the purlin layer 20 thereby forming, between each pair of adjacent purlins, an air pocket which improves the insulation characteristics of the insulation layer.

23.A method of forming an insulation layer according to claim 21 or 22 wherein the corrugated insulation layer having at least two layers one of 25 which is substantially continuous and the other of which is substantially corrugated to provide structure to the insulation layer and to form a plurality of air pockets or cavities within the insulation layer.

24.A method of forming an insulation layer according to claim 23 wherein the at least two layers are substantially adjacent each other. - 26

25.A method of forming an insulation layer according to claim 23 or 24 wherein the at least two layers are formed from an integral piece of material.

26.A method of forming an insulation layer according to claim 23, 24 or 25 5 wherein the one of the at least two layers is folded to form the other of the at least two layers.

27. A method of forming an insulation layer according to any one of claims 23 to 26 wherein one of the at least two layers forms a continuous layer that can extend substantioally over under a roof area and the second of 10 the two layers forms a corrugated effect to provide insulation and air pockets therebetween to improve effective insulation.

28.A corrugated insulation layer which includes a body of fibrous insulation material which contains a lining at least on a first side of the body; wherein the body includes a corrugated first layer and an adjacent 15 second layer which extends substantially continuous along the first layer; wherein the first layer includes a plurality of ridges which define a plurality of cavities in between pairs of adjacent ridges; and wherein the ridges form a support structure for supporting the lining on the first side relative to the second layer. 20

29.A corrugated insulation layer according to claim 28 wherein the first and second layers are manufactured from an integral piece of fibrous material.

30.A corrugated insulation layer according to claim 28 or 29 wherein the integral piece of fibrous material is folded in order to form the ridges of 25 the first layer and to form the second layer.

31. A corrugated insulation layer according to claim 28, 29 or 30 wherein the plurality of ridges are formed at regular intervals. - 27

32.A corrugated insulation layer according to any one of claims 28 to 31 wherein each cavity of the plurality cavities extends into the body from the first side.

33.A corrugated insulation layer according to any one of claims 28 to 32 5 wherein the lining is used to cover the cavities of the first layer thereby to seal the cavities from atmosphere.

34.A corrugated insulation layer according to any one of claims 28 to 33 wherein the body has a thickness which is in the order of between 50 mm and 150 mm; and wherein each cavity has a cross-sectional 10 diameter which between 50% and 80% of the thickness of the body.

35. A corrugated insulation layer according to any one of claims 28 to 34 wherein the body has a thickness which is around 95 mm and each cavity may have a cross-sectional diameter which is around 66% of the thickness of the body. 15

36.A corrugated insulation layer according to any one of claims 28 to 35 wherein the folding of the fibrous material allows at least the first layer to be configured to allow one or more ridges to be collapsed while maintaining the structural integrity of adjacent ridges.

37.A corrugated insulation layer according to any one of claims 28 to 36 20 wherein each cavity is in the form of a groove which extends across a width of the body.

38.A corrugated insulation layer according to any one of claims 28 to 37 wherein the first layer has a thickness which is substantially half of a thickness of the second layer; and wherein the thickness of the second 25 layer is between 70% and 80% of the thickness of the body.

39. A corrugated insulation layer according to any one of claims 28 to 38 wherein the thickness of the layer is about 75% of the thickness of the body. - 28

40.A corrugated insulation layer according to any one of claims 28 to 39 wherein the thickness of the first layer is about 20 mm and the thickness of the second layer is about 65 mm.

41.A corrugated insulation layer according to any one of claims 28 to 40 5 wherein the lining is glued to the first layer.

42.A corrugated insulation layer according to any one of claims 28 to 41 wherein the corrugated insulation layer includes a body of fibrous insulation material which contains a lining on first and second sides of the body; wherein the body comprises of a first layer and an adjacent 10 second layer which extends substantially continuous along the first layer; wherein the first layer is formed using material of the second layer and includes a plurality of ridges which define a plurality of cavities in between pairs of adjacent ridges of the plurality of ridges; and wherein the ridges form a support structure for supporting the lining on the first 15 side of the body relative to the second layer thereby allowing the lining to cover the plurality of cavities.

43. A method of forming an insulation layer which includes the steps of: a. forming a fibrous sheet body having a first layer and a second layer which extends substantially continuously adjacent the first 20 layer; and b. forming the first layer to include a plurality of ridges thereby to define a cavity between each pair of adjacent ridges of the plurality of ridges and thereby to provide support to a lining which extends across an outer side of the body and which covers the 25 cavities.

44.A method of forming an insulation layer according to claim 43 wherein the first layer is folded to form the plurality of ridges.

45.A method of forming an insulation layer according to claim 43 or 44 wherein the first and second layers are formed from an integral piece of -29 material and wherein folding of the material causes the first layer to include a plurality of ridges and causes the second layer to be formed adjacent the first layer and to extend substantially continuous adjacent the first layer. 5

46.A method of forming an insulation layer according to claim 43, 44 or 45 which includes the steps of: a. forming a plurality of folds in an integral piece of fibrous material to form a fold profile in a fibrous body which causes the body to have a first layer which is substantially corrugated through a 10 plurality of ridges formed by the plurality of folds and a second layer which extends substantially continuous adjacent the first layer; b. securing the plurality of folds relative to each other thereby to maintain the fold profile of the fibrous body; and 15 c. covering a first side of the fibrous body thereby covering cavities formed between adjacent pairs of ridges of the plurality of ridges.

47.A method of forming an insulation layer according to claim 45 wherein the fibrous body is lined at opposed first and second sides thereof thereby to secure the plurality of folds relative to each other and to cover 20 the plurality of cavities.

48.A method of forming an insulation layer according to claim 46 or 47 wherein the fold profile may allow the body to be configured so that one or more ridges of the plurality of ridges are capable of being collapsed while maintaining structural integrity of adjacent ridges. 25

49.A method of forming an insulation layer according to claim 46, 47 or 48 wherein the lining is attached to the second layer thereby to secure the fold profile of the fibrous body using the lining of the second side. -30

50.A method of forming an insulation layer according to any one of claims 46 to 49 wherein the plurality of ridges provide a support structure thereby to support the lining of the first end of the fibrous body.

51.A support layer for use in a corrugated insulation layer having an 5 insulation material and used with a roof structure having a support structure; the support layer includes a body of sheet material which is formed to have a corrugated profile when extending longitudinally over the support structure thereby to cause the supported insulation material to have a corrugated profile when extending longitudinally across the 10 purlins thereby to define a number of air pockets above the corrugated insulation material in between each the pair of adjacent purlins of the plurality of purlins.

52.A corrugated insulation layer substantially as hereinbefore described with reference to any one or more of the drawings. 15

53.A method of forming an insulation layer substantially as hereinbefore described with reference to any one or more of the drawings.