WO2009127032A1

WO2009127032A1 - Building insulation utilizing foam panels

Info

Publication number: WO2009127032A1
Application number: PCT/CA2008/000714
Authority: WO
Inventors: Erwin Boeck
Original assignee: Wallsystems International Ltd.; Quad-Lock Building Systems Ltd.
Priority date: 2008-04-15
Filing date: 2008-04-15
Publication date: 2009-10-22

Abstract

A wall (60) is insulated by fastening panels (50, 52) to the wall using a plurality of ties (10). Each tie has a plate (20) and vertically extending planar members (12, 14). A track (62) is fixed along the base of the wall. A first row of panels (64) is horizontally abutted to one another, atop the track. Downwardly extending planar members of a plurality of ties are inserted into the first row panels at spaced intervals along the first row. The ties' plates are fastened to the wall. A second row of panels is then horizontally abutted to one another, atop the first row, by inserting upwardly extending planar members of the ties into the second row panels at spaced intervals along the first and second rows. The abutting, inserting and fastening steps are sequentially repeated for further rows of panels until the wall is covered with panels.

Description

BUILDING INSULATION UTILIZING FOAM PANELS

Technical Field

[0001] This disclosure pertains to insulation of an existing building wall by fastening insulation panels to the wall.

Background

[0002] It is often desirable to insulate the walls of an existing building. This can be done in various ways. For example, insulation panels can be glued to an existing wall. However glue may not form an adequate bond in some cases, e.g. if the wall's surface is dirty, uneven, decaying, etc. A glue bond may also deteriorate over time, in which case the panels may become dislodged from the wall, particularly if the wall is exposed to high winds, severe rain, etc. [0003] Insulation panels can also be fastened to a wall using metal fasteners such as screws or nails. Although this may securely attach the panels to the wall, each fastener forms a thermal bridge through the insulation. Thermal bridges can adversely affect the panels' insulation capability. For example, if the panels' outer surfaces are covered with a finishing material such as stucco, thermal bridges may result in condensation, eventually causing unsightly marks to appear on the stucco adjacent each fastener.

[0004] Insulation panels can also be fastened to a wall using metal or plastic tracks pre-fastened to the wall at spaced intervals. The panels are slidably inserted into and securely held by the tracks. However, the tracks and the fasteners which attach the tracks to the wall can form thermal bridges, which is undesirable as noted above. The tracks can also disrupt the application of finishing materials such as stucco to the wall. [0005] United States Patent No. 5,704, 180 issued 6 January 1998 discloses wall formation with the aid of an insulating concrete form system utilizing foam panels and connectors.

[0006] International (PCT) Patent Application Publication No. WO2007/ 140570 dated 13 December 2007 discloses joinder of horizontal concrete slabs to vertical walls formed in accordance with the ' 180 patent. [0007] As explained below, the foregoing disadvantages can be addressed by fastening to an existing building wall foam (i.e. insulation) panels like those disclosed in the ' 180 patent and in the '570 publication. [0008] The foregoing examples of the related art and limitations related thereto are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings.

Brief Description of Drawings [0009] Exemplary embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than restrictive.

[0010] Figure 1 is front elevation view of a tie for coupling an insulation panel to a wall. [0011] Figure 2 is an oblique top front isometric view of the Figure 1 tie.

[0012] Figure 3 is an oblique top rear isometric view of the Figure 1 tie.

[0013] Figure 4 is a top plan view of the Figure 1 tie. [0014] Figure 5 is a left side elevation view of the Figure 1 tie.

[0015] Figure 6 is an oblique bottom front isometric view of the

Figure 1 tie.

[0016] Figure 7 is an isometric illustration showing the Figure 1 tie coupling a pair of insulation panels to a wall. [0017] Figure 8 is a partially fragmented isometric illustration showing a plurality of Figure 1 ties coupling a plurality of insulation panels to an exterior wall.

[0018] Figure 9 is a partially fragmented isometric illustration showing a plurality of Figure 1 ties coupling a plurality of insulation panels to two interior walls. Description

[0019] Throughout the following description specific details are set forth in order to provide a more thorough understanding to persons skilled in the art. However, well known elements may not have been shown or described in detail to avoid unnecessarily obscuring the disclosure.

Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense.

[0020] Terms such as horizontal, vertical, vertically extending, above, below, upper, lower, front, rear, etc. are relative. As used herein, such terms correspond to the orientations depicted in the drawings as described below.

[0021] Figures 1—6 depict a tie 10 for coupling an insulation panel to a wall as explained below. Tie 10 has at least one and preferably two parallel, vertically extending planar members 12, 14. Bars 16, 18 extend transversely between plate 20 and planar members 12, 14 to hold planar members 12, 14 in fixed, spaced, parallel, coplanar relationship to one another, and in transverse opposition to plate 20. The vertical extension of each of members 12, 14 away from (i.e. above and below) bars 16, 18 is substantially equal, but may be unequal. Bars 16, 18 are rigidly intercon- nected by brace 22 to assist in maintaining a fixed displacement between bars 16, 18. The ends of bars 16, 18 flare outwardly and upwardly or downwardly to merge with the outer ends of the respective planar members, as illustrated, for example, by reference numerals 24, 26, 28, 30. This enhances tie 10's structural integrity. The cross-sectional shape of bars 16, 18 and brace 22 is arbitrary.

[0022] A lower central portion of plate 20 may be apertured, as indicated at 31, to reduce the weight of plate 20 and reduce the cost of the material required to form plate 20, but without compromising the structural integrity of plate 20. This gives plate 20 an inverted-U shape, best seen in Figure 3. Formation of aperture 31 yields third and fourth vertically extending planar members 32, 34 which protrude downwardly. Members 32, 34 assist in bracing tie 10 against a wall to prevent tilting of - A -

tie 10 when tie 10 is attached to a wall as explained below. Aperture 31 may be omitted, and plate 20 may have any desired shape. [0023] An aperture 36 (or a suitably weakened location— not shown) is provided in plate 20 to receive a fastener for fastening tie 10 to a wall as explained below. Tie 10 may be made of a suitable plastic material such as high density polyethylene (HDPE) or polypropylene (PP). [0024] Figure 7 depicts a pair of expanded polystyrene foam insulation panels 50, 52 horizontally abutted to one another along vertical joint 54. Panels 50, 52 are horizontally interlocked by extending the lower halves of tie 10's planar members 12, 14 into passages formed in the upper ends of each of panels 50, 52 as shown in Figure 7 and as explained in the ' 180 patent. More particularly, the lower half of planar member 12 is extended into a passage formed in the upper end of panel 50, and the lower half of planar member 14 is extended into a passage formed in the upper end of panel 52. Tie 10 thus bridges across joint 54, horizontally interlocking panels 50, 52. The rearward face of tie 10's plate 20 is placed against wall 56 (e.g. a concrete block wall), and fastener 58 (e.g. a masonry screw) is driven through tie 10's aperture 36 to securely fasten tie 10 to wall 56, thereby coupling panels 50, 52 to wall 56. [0025] If wall 56 is a wood or metal stud wall, then panels 50, 52 or tie 10, or both, can be shifted to centre tie 10's plate 20 over a pre-located stud within wall 56. Fastener 58 (e.g. a decking screw) can then be driven through tie 10's aperture 36 to securely fasten tie 10 to the pre-located stud, thereby coupling panels 50, 52 to wall 56. [0026] Figure 8 depicts affixation of a plurality of insulation panels to an exterior wall 60, utilizing a plurality of ties 10. A metal track 62 is horizontally levelled and fixed along the base of wall 60. A first row, 64, of insulation panels is then horizontally abutted to one another atop and within track 62. The upper ends of each adjacent pair of panels in first row 64 are then horizontally interlocked by extending the lower halves of one of a tie 10's planar members 12, 14 into passages formed in the upper ends of the two respective panels, as explained above in relation to Figure 7, while maintaining each tie lO's plate 20 parallel to and against wall 60. Fasteners are then driven through each aperture 36 of each tie 10 to securely fasten ties 10 to wall 60, thereby coupling the horizontally interlocked panels in first row 64 to wall 60. [0027] A second row, 66, of insulation panels is then horizontally abutted to one another atop first row 64. More particularly, the lower ends of each adjacent pair of panels in second row 66 are horizontally interlocked by fitting passages formed in the respective panels' lower ends over the upper halves of planar members 12, 14 of one of the ties 10 used to horizontally interlock the adjacent upper ends of a pair of panels in first row 64. Panels in second row 66 are horizontally offset with respect to panels in first row 64, to offset the joints between pairs of horizontally abutted panels in second row 66 from the joints between pairs of horizontally abutted panels in first row 64. After the second row panels' lower end passages are fitted over ties 10 as aforesaid, the second row panels are forced downwardly until their lower ends contact the upper ends of the panels in first row 64. Thus, as well as being horizontally interlocked, the lower ends of the panels in second row 66 are also vertically interlocked to the upper ends of the panels in first row 64 since the upper halves of the ties' planar members 12, 14 extend upwardly within the second row panels. Both the upper ends of the panels in first row 64 and the lower ends of the panels in second row 66 are accordingly securely fastened to wall 60 by ties 10. [0028] The upper ends of each adjacent pair of panels in second row 66 are then horizontally interlocked by extending the lower halves of another tie 10' s planar members 12, 14 into passages formed in the upper ends of the two respective panels, as explained above in relation to Figure 7, while maintaining each tie lO's plate 20 parallel to and against wall 60. Fasteners are then driven through each aperture 36 of each tie 10 to securely fasten ties 10 to wall 60, thereby coupling the upper ends of the horizontally interlocked panels in second row 64 to wall 60. [0029] A third row, 68, of insulation panels is then horizontally

^U, ac ends of each adjacent pair of panels in third row 68 are horizontally interlocked by fitting passages formed in the respective panels' lower ends over the upper halves of planar members 12, 14 of one of the ties 10 used to horizontally interlock adjacent upper ends of a pair of panels in second row 66. Panels in third row 68 are horizontally offset with respect to panels in second row 66, to offset the joints between pairs of horizontally abutted panels in third row 68 from the joints between pairs of horizontally abutted panels in second row 66. After the third row panels' lower end passages are fitted over ties 10 as aforesaid, the third row panels are forced downwardly until their lower ends contact the upper ends of the panels in second row 66. Thus, as well as being horizontally interlocked, the lower ends of the panels in third row 68 are also vertically interlocked to the upper ends of the panels in second row 64 since the upper halves of the ties' planar members 12, 14 extend upwardly within the third row panels. Both the upper ends of the panels in second row 66 and the lower ends of the panels in third row 68 are accordingly securely fastened to wall 60 by ties 10.

[0030] The upper ends of each adjacent pair of panels in third row 68 are then horizontally interlocked by extending the lower halves of another tie 10' s planar members 12, 14 into passages formed in the upper ends of the two respective panels, as explained above in relation to Figure 7, while maintaining each tie 10 's plate 20 parallel to and against wall 60. Fasteners are then driven through each aperture 36 of each tie 10 to securely fasten ties 10 to wall 60, thereby coupling the upper ends of the horizon- tally interlocked panels in third row 68 to wall 60.

[0031] In similar fashion, fourth, fifth, sixth and seventh rows 70, 72, 74, 76 are sequentially horizontally abutted to one another atop the previously formed rows, and further pluralities of ties 10 are used to horizontally interlock the lower ends of the panels in each row to one another, to vertically interlock the lower ends of the panels in each row to the upper ends of the panels in the adjacent lower row, and to fasten the panels in each row to wall 60. Sufficiently many rows of insulation panels αrp -Fα ctAriArl tn

αnrl tVinc inciii citA Tf necessary, the panels used to form the uppermost row can be trimmed to fit the space between the top of the wall and the upper ends of the panels in the adjacent lower row of panels.

[0032] Within each row, portions of endmost panels can be allowed to protrude beyond the outward ends of wall 60. Such protruding endmost panel portions can then be trimmed, e.g. with a dry wall saw or a hot-knife tool, leaving the ends of each row of panels flush with the outward ends of wall 60. Similarly, the panels can be trimmed around wall openings or protrusions. Ties 10 are advantageously fitted into the panels and fastened to the wall near such openings or protrusions, to provide attachment points for finishing materials which can be subsequently applied to the panels as explained below. A cap 78 can be provided atop the uppermost row of panels. [0033] A finishing material 80, such as stucco, can be applied to the outward faces of the panels fastened to wall 60. Alternatively, furring strips (not shown) can be glued or screwed to the outward faces of the panels fastened to wall 60 to support lapped siding or shingles. This can be achieved by ensuring that within each row, some (or possibly all) ties 10 are spaced at standard intervals (e.g. 24 inches or 610 mm). The furring strips can then be fastened to the outward faces of the panels fastened to wall 60 in conventional fashion, e.g. by driving screws through the furring strips into one or the other of the planar members 12, 14 of the appropriately spaced ties 10. [0034] Figure 9 depicts affixation of a plurality of insulation panels to an interior wall 90, utilizing a plurality of ties 10. The procedure for fastening insulation panels to interior wall 90 is substantially similar to that described above in relation to exterior wall 60 and Figure 8. A finishing material 92, such as dry wall sheets, can be applied to the outward faces of the panels fastened to wall 90. This is achieved by ensuring that within each row, some (or possibly all) ties 10 are spaced at standard intervals (e.g. 24 inches or 610 mm), corresponding to the standard spacing of studs used to form interior walls. The dry wall sheets can then be fastened to the e.g. by driving dry wall fastening screws through the dry wall sheets into one or the other of the planar members 12, 14 of the appropriately spaced ties 10.

[0035] Use of ties and insulation panels as aforesaid provides uninter- rupted insulation on the wall, without facilitating formation of thermal bridges through the insulation, and without disrupting the application of finishing materials such as stucco to the insulation. The ties securely fasten the panels to the wall in a manner capable of withstanding high winds, severe rain, etc. [0036] If it is desired to insulate a wall bearing a finishing material such as stucco, the finishing material need not be removed from the wall— ties 10 can be fastened directly to the stucco-coated (or other finish- covered) wall as explained above. Similarly, ties 10 can be fastened directly to a wall surface which is dirty, uneven, etc. without the need for significant preparation of the wall surface.

[0037] While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. For example, as explained in the ' 180 patent, mating protrusions 92 (Figure 7) and recesses (not shown) may be formed at regularly spaced intervals along the panels' upper and lower surfaces to facilitate vertical alignment of panels atop one another. Such protrusions and recesses also facilitate interlocking of the panels along the horizontal joints between vertically adjacent panels, improving the insulating capability of the panels when they are applied to a wall as aforesaid. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations as are within their true spirit and scope.

Claims

WHAT IS CLAIMED IS:

1. A tie (10) for coupling an insulation panel to a wall, the tie comprising: a plate (20) attachable to the wall; and at least one bar (16 or 18) transversely connecting the plate (20) to at least one vertically extending planar member (12 or 14) transversely opposed to the plate (20).

2. A tie as defined in claim 1, further comprising: a first bar (16) connecting the plate (20) to a first vertically extending planar member (12) transversely opposed to the plate (20); a second bar (18) connecting the plate (20) to a second verti- cally extending planar member (14) transversely opposed to the plate (20).

3. A tie as defined in claim 2, further comprising a brace (22) coupled between the first bar (16) and the second bar (18).

4. A tie as defined in claim 3, further comprising a weight and material reducing aperture (31) formed in the plate (20).

5. A tie as defined in claim 4, wherein the aperture (31) is formed in a lower central portion of the plate (20).

6. A tie as defined in claim 3, wherein the plate (20) has an inverted-U shape.

7. A tie as defined in claim 3, further comprising third and fourth vertically extending planar members (32, 34) protruding downwardly from the plate (20).

8. A method of insulating a wall, the method comprising: providing a plurality of ties, each tie having at least one bar connecting a plate to at least one vertically extending planar member transversely opposed to the plate; fixing a track along a base of the wall; horizontally abutting a first row of insulation panels atop the track; for each panel in the first row, inserting the vertically extending planar member of at least one of the ties into an aperture extend- ing downwardly into the panel in the first row, while maintaining the plate of the at least one of the ties parallel to the wall, then fastening the plate of the at least one of the ties to the wall; horizontally abutting a second row of insulation panels atop the first row and for each panel in the second row, inserting the vertically extending planar member of the at least one of the ties into an aperture extending upwardly into a panel in the second row; for each panel in the second row, inserting the vertically extending planar member of at least another one of the ties into an aperture extending downwardly into the panel in the second row, while maintaining the plate of the at least another of the ties parallel to the wall, then fastening the plate of the at least another of the ties to the wall; and sequentially repeating the abutting, inserting, maintaining and fastening steps for further insulation panels until the wall is covered with insulation panels.

9. A method as defined in claim 8, wherein each tie further comprises at least one pair of transversely opposed vertically extending planar members, the method further comprising, for each horizontally adjacent pair of the panels: inserting a first vertically extending planar member of a selected tie into an aperture extending downwardly into a first one of the horizontally adjacent panels; and inserting a second vertically extending planar member of the selected tie into an aperture extending downwardly into a second one of the horizontally adjacent panels.