GB2421741A

GB2421741A - Clip for supporting insulation board

Info

Publication number: GB2421741A
Application number: GB0427606A
Authority: GB
Inventors: Digby Harper
Original assignee: Celotex Ltd
Current assignee: Celotex Ltd
Priority date: 2004-12-16
Filing date: 2004-12-16
Publication date: 2006-07-05
Also published as: GB0427606D0

Abstract

A clip 1 for supporting an insulation board 17 against a rafter comprises a body 2 for location between the board 17 and the rafter, and having opposed first and second sides 3, 4, one or more support members 9 extending from second side 4, and at least part 5 of the first side 3 is convex. As shown, pins 9 penetrate board 17, whilst surface 5 bears against the rafter, aided by ribs 6a, 6b, and 6c.

Description

A Clip for Insulation Boards The present invention relates to a clip, in

particular a clip for supporting an insulation board against a rafter.

Rigid, thermally insulating boards or panels, as used in the construction industry, are typically made from foamed materials, commonly closed cell insulating materials such as polyurethane, polyiso-cyanurate, polystyrene or phenolic foams. Alternatively, non-foam insulating materials such as mineral wool can be used. In most cases the foam boards will be faced with a flexible sheet material such as paper, metal, plastics, glass fibre and various laminated or coated combinations.

The facing may consist of a multi-layer lamination or multi-coatings, the layer adjacent to the foam may auto- adhesively bond to the foam system by chemical, physical or mechanical means, using, for instance polyethylene, possibly in combination with glass fibre tissue.

Insulation boards are often placed in a loft cavity of a building, most often between the rafters of a roof.

Insulating boards are commonly supported between two rafters either by affixing the board directly to the rafters, by means of, for instance, glue, nails or screws, or by placing a strip of material across the face of a rafter and the adjacent face of the board and affixing the strip to the rafter and board, again by means of glue, nails or screws.

An insulation board can be supported between two rafters using these techniques of the prior art, but it can be time consuming to fit an insulation board. Removal of the board once it has been affixed to the rafter can be also be time consuming, especially if nails or screws are used, since each nail/screw will need to be removed individually.

Published UK patent applications GB-A-2331958 and GB-A- 2303156, which were filed in the name of Yorkshire Building Services (Whitwell) Limited, describe the use of T-shaped clips for roof cladding elements and cavity closures, respectively. GB-A-2303156 describes a T- shaped clip having a flat body portion, for insertion between a surface of a vertical wall and the edge of a cavity closure, and one or more pins projecting from flat body for insertion into an edge of the cavity closure. The top of the T' is formed by two flat members, one of which, in use, will contact a face of the cavity closure and the other of which will be in contact with and be affixed to an adjacent, parallel surface of the wall. Although these clips allow facile attachment of the clip to a cavity closure, one must nevertheless attach the clip via the plate- like member to a surface by means such as adhesive, nails or screws. Generally, these T'-shaped clips are able to perform the task of holding a cavity closure in place, but they are somewhat inconvenient if it is then desired to quickly remove the cavity closure.

It is an aim of the present invention to overcome or mitigate at least some of the problems associated with the

prior art.

The present invention provides a clip for supporting an insulation board against a rafter, the clip comprising a body for location between the insulation board and the rafter, the body having a first side and a second side opposing the first side, one or more support members extending from the second side of the body, wherein at least part of the first side of the body is convex.

"Convex" includes within its definition "projecting outwards", and preferably "curving outwards". "Projecting outwards" includes a projection outwards from the surface which may have a cross-section that is not necessarily curved, for instance a triangular cross section. "Curving outwards" includes shapes which have a curved cross section.

The present invention will now be further described.

In the following passages different aspects of the invention are defined in more detail. Each aspect so defined may be combined with any other aspect or aspects unless clearly indicated to the contrary. In particular any feature indicated as being preferred or advantageous may be combined with any other feature or features indicated as being preferred or advantageous.

The convex part of the first side of the body acts, in use, to frictionally engage with a surface and will be much more effective in doing so than a flat surface of a clip of the same material. The first side of the body may comprise a single convex part or two or more convex parts. The convex part may be in the form of a dimple. The convex part may be in the form of a rib and extend across part or all of the first side, preferably in a direction transverse to the length of the body.

The apex of the convex surface may be raised from 1 mm to 4 mm above the surrounding surface of the first side.

Preferably, the convex part of the first surface has a width, measured along the length of the body, of from 0.5 cm to 3 cm, preferably 1 to 2 cm, preferably about 1.5 cm.

Preferably, the clip further comprises one or more projections extending from the first side of the body. The one or more projections are preferably suitable for engagement with the grooves and indents formed by the grain of the wood of the rafter. It has been surprisingly found that the projections improve the frictional engagement of the clip with a surface, particularly if the surface is textured, such as a grained surface of a piece of wood. The one or more projections may be dimples. The one or more projections may be ribs. Preferably, the projections have a rounded surface, since this allows smooth movement over a textured, possibly rough, surface of a rafter, as an insulation board is being inserted against the rafter. One or more ribs may extend across part or all of the first side, preferably in a direction transverse to the length of the body. One reason this is preferable is that the clip may be a moulded clip, possibly moulded in a two-part mould, the join of which extends along the centre of each of the first and second sides of the clip along the length of the body. Removal of a moulded clip from such a two-part mould is relatively facile if the projections are ribs which extend across the first surface in a direction transverse to the length of the body.

Preferably, the projections project a maximum of 3 mm from the surrounding surface, more preferably a maximum of 2 mm, even more preferably a maximum of 1mm. Preferably, the one or more projections have a width, measured across the projection on the first surface, of 0.25 mm to 3mm, preferably 0.5 to 1.5 mm. If the projections are ribs extending across the first side in a direction transverse to the length of the body, the width of the rib is measured in the direction of the length of the body.

The one or more projections are preferably located on the convex part of the first side of the body.

Preferably, a part of the second side of the body, corresponding to the convex part of first side of the body, is concave. Preferably, the shape of the concave part of the second side corresponds to that of the convex part of the first side. Preferably, the position of the concave part of the second side corresponds to the position of the convex part of the first side. Preferably, the convex part of the first side is in the form of a rib extending across the first side, in a direction transverse to the length of the body and the concave part of the second side is of a corresponding shape and orientation such that the body comprises a bowed section. It has been surprisingly found that such a bowed section of the body has a number of advantages, one being that if the clip is made from resilient material, there will be a degree of flexibility in the bowed section of the clip. Additionally, compared to a clip which has a flat second surface, the clip can be produced with less material while still maintaining sufficient resilience. The bowed section of the clip should be sufficiently resilient, such that, when the clip is frictionally supporting a board against a rafter, the bowed section is not pressed flat. The bowed section preferably has a thickness, measured from the first side to the second S side, of at least 1 mm, preferably of from 1 mm to 4mm, still more preferably of from 2 to 3 mm, most preferably about 2.5 mm (particularly if the clip is made from a plastic material such as nylon, polypropylene or polyethylene) "Concave" includes within its definition "projecting inwards", preferably "curving inwards". "Projecting inwards" includes a projection into the surface which may have a cross-section that is not necessarily curved, for instance a triangular cross section. "Curving inwards" includes shapes which have a curved cross section.

The clip may comprise one or more support members for insertion into a foam material of the insulation board. The one or more support members may be tapered towards its/their free end for insertion of the member into a foam material of the insulation board. The one or more support members may be in the form of pins, preferably being tapered toward their free ends. A tapered end and preferably a rounded tapered end is preferred since this is easier to insert and also less prone to damage or pierce the cells of a closed cell foam when the support member is inserted into an insulation board, compared to, for example, a flat-ended insertion member. It is undesirable to damage or pierce the cells of the foam since this will decrease an insulation board's insulating properties and, if moving the board, the clip member is more likely to fall out of the foam because the member will be frictionally held less tightly within the foam. The clip may comprise two or more support members for insertion into a foam material of the insulation board, and two of these support members for insertion into a foam material of the insulation board may be located on either side of a concave part of the second side.

The one or more support member(s) for insertion into a foam material of the insulation board may be tapered towards its/their free end. The support members for insertion into a foam material may be round in cross section or have a simple polygonal shape in cross section, e.g. be rectangular, square or triangular. The size and shape of the cross section may be uniform along the length of the support member, until its tapering end, if present.

Preferably, the length of the support members for insertion into a foam material is from 1 cm to 4 cm, more preferably of from 1.5 cm to 2 cm. A support member for insertion into a foam material of the insulation board may have a width, measured in a direction along the length of the body, that is more than the width of the support member, measured in a direction transverse to the length of the body. This can allow a support member to have the required strength, in use, to support the weight (or part thereof) of an insulation board, and compared to a supporting member, in which the widths along and transverse to the length of the body are the same, the amount of material required for a support member is decreased. Preferably, the width, measured in a direction along the length of the body, is of from 2 to 5 mm, more preferably 3 to 4 mm. Preferably, the width, measured in a direction transverse to the length of the body is of from 0.75 to 2.5 mm, preferably of from 1 to 2mm.

The support member may be a base support member, which may be in addition to, or in place of, the support member for insertion into the foam of an insulation board. If the clip does not comprise a support member for insertion into the foam, it should comprise a base support member, to which an insulation board can be adhered, by chemical or mechanical means. A "base support member" includes, but is not limited to, a flat platelike member. A first base support member may extend laterally from one end of the body, such that the base support member and the body together form an approximate L shape.

The clip may comprise a second base support member extending laterally from the same end of body as the first base support member in a direction opposite to the first support member, such that the body, first and second base support members together form an approximate T shape.

The free ends of the first and/or second base support members may be rounded. The base support member is preferably a plate-like member having a thickness of from 0.5 to 4 mm, preferably of from 1 to 2 mm, most preferably about 1.5 mm. The base support member is preferably of the same width, measured in a direction transverse to the length of the body, as the body of the clip. The width is preferably of from 0.5 to 3 cm, preferably about 1 cm. The length of the base support member is preferably of from 1 to 4 cm, preferably of from 2.5 to 3.5 cm.

The clip preferably comprises a resilient material, preferably a plastic or a metal. Plastic is preferred since it is generally sufficiently lightweight and flexible to form a clip that is quick and economical to produce, preferably by moulding. The plastic may be selected from polypropylene, polyethylene, nylon or mixtures thereof. The clip may be an integrally moulded clip.

The clip may be provided with a lip at a free end of the body. This free end' is the end of the clip intended to be the part of the clip which will first contact the surface of a rafter when an insulation board is being inserted into place against the rafter. The lip is a part of the body that is angled toward the supporting members, such that if during insertion of the board the lip first contacts a corner of a rafter, rather than the surface against which the clip should rest, the clip will be guided by means of the lip to the side of the rafter.

The present invention further provides an insulation board having attached thereto one or more clips of the present invention. The insulation board may comprise a foam material located between two facings, the board having a top and a bottom face, each formed by one of the facings, and sides. At least two clips of the present invention may be attached to opposing sides of the board. The foam is preferably a closed cell foam material, preferably comprising a polyurethane, a polyiso- cyanurate, a polystyrene, a phenolic foam, or a mixture thereof. The facing may comprise a sheet material such as paper, metal, - 10 - plastics, glass fibre and various laminated or coated combinations thereof. The metal may be aluminium or steel.

The present invention further provides an insulation board frictionally supported between two opposing surfaces by means of two or more clips of the present invention.

The present invention further provides a kit comprising an insulation board and one or more clips of the present invention.

The present invention will now be described by way of example only with reference to one of the following drawings, in which: Figure 1 shows a perspective view of an embodiment of a clip of the present invention, Figure 2 shows a side view of a clip of the present invention, Figure 3 shows a view of the clip along the direction A, Figure 4 shows a cross section of a typical roof comprising roof tiles, tile battens, roof felt and rafters.

It is desirable for there to be a minimum of 50 mm between the upper surface of an insulation board and the roof felt.

The insulation board is being frictionally supported by the clip of Figures 1 to 3 against the shown rafter.

- 11 -

Example

The clip 1 illustrated in Figures 1 to 4 has a relatively thin elongate body 2 with a first side 3 and a second side 4 opposing the first side 3. The first side 3 has a convex part 5 located approximately in the central portion of the elongate body. Three projections 6a, 6b and 6c in the form of ribs are located on the convex part of the first side. The ribs extend across the first surface in a direction perpendicular to the length of the body (indicated by direction B) . The second side comprises a concave part 7 corresponding to, i.e. in a position opposite to, the convex part of the first side. Together the convex part of the first side and concave part of the second side form a bow- shaped portion 8 of the body. Two supporting members in the form of pins 9 for the insertion into a board extend from the second side. The two pins 9 are each located on a flat part of the second side on either side of the concave part of the second side. The pins are rectangular in cross section and taper toward a point 10 at their free end 11. A base support member 12 extends laterally from one end of the body in the same direction as the pins. The base support member is an elongate plate having a rounded end. A second base support member 13 extends from the same end of the body in a direction opposite to the first base support member.

The second base support member is an elongate plate having a rounded end. A lip 14, is located at the free end 15 of the body. The first side of the body forming the lip forms an angle greater than 180 degrees with a flat part 16 of the first side of the body. The angle shown in Figure 2 is approximately 225 degrees.

- 12 - The clip 1 can be used to support an insulation board against a rafter by first inserting the pins of the clip through the edge of the board into the insulation material 17, using the base support member as a guide to ensure the length of the body is approximately perpendicular to a side 18 of the insulation board and in line with an edge 18a of the board. The base support member 12 contacts a side 18 of the insulation board, formed by a facing (not shown) of the board. A second clip (not shown), identical to the first clip is then inserted into the board on an opposite edge of the board (not shown) . More clips (not shown) are then inserted on each opposing side of the board at an approximate separation of 20 to 30 cm. The board is then inserted between two rafters 19 such that the first side of each clip contacts the inner side of the rafter 20, and the board gently pressed into an installation position, i.e. a position where the second base support member 13 contacts the underside 21 of the rafter. The underside 21 of the rafter and the underside 18 of the board are thus approximately at a similar level and parallel, as shown in Figure 4. The convex part of the first side and ribs thereon frictionally support each end of the insulation board against the rafter. The insulation board may be removed from its installation position by simply pulling the board at one of its edges to overcome the frictional force of the clips which hold the insulation board in place.

As illustrated in the Example, the clip of the present invention is suitable for use in supporting insulation boards between rafters. Generally, rafters are at an - 13 - inclined angle, for instance in a roof space and when an insulation board is supported between these rafters, the base support members, if present, will be located on the underside of the board.

The clip of the present invention can also be suitable for suspending an insulation board as part of under-floor insulation. Such a clip will preferably comprise a first base support member which extends laterally from one end of the body, such that the first base support member and the body together form an approximate L shape. The first base support member will preferably extend laterally from the body in the same direction as the convex part of the first side to allow the support member, in use, to rest on an upper surface of a floor beam. An insulation board having clips on opposing sides of the board may then be supported between the horizontal floor beams. The clip for under floor insulation boards will preferably comprise support members extending from the second side, as herein described.

The clip for under floor insulation boards may have other features as herein described.

Claims

- 14 - Claims: 1. A clip for supporting an insulation board against a

rafter, the clip comprising a body for location between the insulation board and the rafter, the body having a first side and a second side opposing the first side, one or more support members extending from the second side of the body, wherein at least part of the first side of the body is convex.
2. A clip as claimed in claim 1, wherein the clip further comprises one or more projections extending from the first side of the body.
3. A clip as claimed in claim 2, wherein the one or more projections are dimples.
4. A clip as claimed in claim 2, wherein the one or more projections are ribs.
5. A clip as claimed in any one of claims 2 to 4, wherein the one or more projections are located on the convex part of the first side of the body.
6. A clip as claimed in any one of the preceding claims wherein a part of the second side of the body, corresponding to the convex part of first side of the body, is concave.

- 15 -
7. A clip as claimed in claim 6, wherein the clip comprises two or more support members for insertion into a foam material of the insulation board, and two of the support members for insertion into a foam material of the insulation board are located on either side of the concave part of the second side.
8. A clip as claimed in any one of the preceding claims, wherein at least one of the one or more of the support member(s) is tapered towards its free end for insertion of the member into a foam material of the insulation board.
9. A clip as claimed in any one of the preceding claims, wherein the clip comprises a first base support member extending laterally from one end of the body, such that the base support member and the body together form an approximate L shape.
10. A clip as claimed in claim 9, wherein the clip comprises a second base support member extending laterally from the same end of body as the first base support member in a direction opposite to the first support member, such that the body, first and second base support members together form an approximate T shape.
11. A clip as claimed in any one of the preceding claims comprising polypropylene, polyethylene, nylon, or a mixture thereof.
12. A clip as claimed in any one of the preceding claims, wherein the clip is an integrally moulded clip.

- 16 -
13. An insulation board having attached thereto one or more clips as defined in any one of the preceding claims.
14. An insulation board comprising a foam material located between two facings, the board having a top and a bottom face, each formed by one of the facings, and sides, wherein two clips as defined in any one of claims 1 to 12 are attached to opposing sides of the board.
15. An insulation board as claimed in claim 14, wherein the board is frictionally supported between two opposing surfaces by means of at least two clips of the present invention.
16. A kit comprising an insulation board and one or more clips as defined in any one of claims 1 to 12.
17. A clip for supporting an insulation board against a rafter substantially as herein described with reference to

the Example.
18. A clip for supporting an insulation board against a rafter substantially as herein described with reference to any one of Figures 1 to 4.