U.S. patent application number 11/561468 was filed with the patent office on 2007-05-03 for insulation batt having integral baffle vent.
This patent application is currently assigned to CertainTeed corporation. Invention is credited to Richard S. Duncan, R. Allan Snyder.
Application Number | 20070094966 11/561468 |
Document ID | / |
Family ID | 46206088 |
Filed Date | 2007-05-03 |
United States Patent
Application |
20070094966 |
Kind Code |
A1 |
Snyder; R. Allan ; et
al. |
May 3, 2007 |
Insulation Batt Having Integral Baffle Vent
Abstract
A baffled insulation product and a method for insulating and
ventilating a space between rafters for supporting a roof includes,
an elongated insulation mat having an integral baffle, at least one
channel on a roof facing side of the baffle for passage of
ventilating air, and at least one vapor permeable membrane covering
at least a portion of the insulation mat facing the channel,
wherein each vapor permeable membrane transmits water vapor
emanating from the insulation mat.
Inventors: |
Snyder; R. Allan;
(Eagleville, PA) ; Duncan; Richard S.;
(Royersford, PA) |
Correspondence
Address: |
DUANE MORRIS, LLP;IP DEPARTMENT
30 SOUTH 17TH STREET
PHILADELPHIA
PA
19103-4196
US
|
Assignee: |
CertainTeed corporation
|
Family ID: |
46206088 |
Appl. No.: |
11/561468 |
Filed: |
November 20, 2006 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10996225 |
Nov 23, 2004 |
|
|
|
11561468 |
Nov 20, 2006 |
|
|
|
Current U.S.
Class: |
52/309.1 |
Current CPC
Class: |
E04D 13/1625 20130101;
E04D 13/178 20130101; E04C 1/00 20130101; E04D 13/172 20130101 |
Class at
Publication: |
052/309.1 |
International
Class: |
E04C 1/00 20060101
E04C001/00 |
Claims
1. A baffled insulation product for insulating and ventilating a
space between rafters, said rafters being used for supporting a
roof, comprising: an elongated insulation mat having an integral
baffle; at least one channel on a roof facing side of the baffle
for passage of ventilating air; and at least one water vapor
permeable membrane covering at least a portion of the insulation
mat facing the channel, wherein said water vapor permeable membrane
permits a transmission of water vapor emanating from the insulation
mat into said channel.
2. The insulation product of claim 1, wherein the insulation mat
comprises, a foam, a fibrous web or a combination thereof.
3. The insulation product of claim 1, wherein the vapor permeable
membrane is substantially impervious to liquid water to prevent
ambient condensate from seeping into
4. The insulation product of claim 1, wherein the vapor
permeability of the water vapor permeable membrane increases with
increases in the relative humidity inside the insulation mat.
5. The insulation product of claim 1, wherein the baffle is between
wings of the insulation mat.
6. The insulation product of claim 1, wherein the water vapor
permeable membrane covers a perforated area of the baffle.
7. The insulation product of claim 1, wherein the baffle is
attached to the insulation mat and the water vapor permeable
membrane.
8. The insulation product of claim 1, wherein the vapor permeable
membrane is located between the insulation mat and the channel.
9. The insulation product of claim 1 wherein, the baffle has a
perforated area, the vapor permeable membrane covers the perforated
area, and the vapor permeable membrane is located on, either the
baffle, or the insulation mat.
10. The insulation product of claim 1, further comprising: a water
vapor retarder on a bottom major surface of the insulation; and the
water vapor permeable membrane transmits water vapor due to excess
moisture build up in the insulation mat behind the vapor
retarder.
11. The insulation product of claim 1, further comprising: a
separator extending through the insulation and the baffle for
separating the insulation product into pieces.
12. The insulation product of claim 1, wherein the baffle is
adapted for the passage of the ventilating air by comprising; a
least one open channel, or a corrugated channel having a plurality
of open channels, or a porous channel comprised of, a matting or
ventilation mesh.
13. The insulation product of claim 1, wherein the baffle
comprises, a corrugated channel having a plurality of open channels
for the passage of the ventilating air.
14. The insulation product of claim 1, wherein the baffle
comprises, a least one open channel for the passage of the
ventilating air.
15. The insulation product of claim 1, wherein the baffle
comprises, a porous channel comprised of, a matting or ventilation
mesh, for the passage of the ventilating air.
16. A method of insulating and ventilating a space between rafters
for supporting a roof, comprising: (a) assembling an insulation
product with an insulation mat integral with a baffle having at
least one open channel extending the length of the insulation mat,
and a water vapor permeable membrane covering at least a portion of
the insulation mat that faces toward the baffle; and (b) installing
the insulation product in a space between adjacent rafters for
supporting a roof of a building, with the channel facing toward an
under surface of the roof for passage of ventilating air along the
space between the adjacent rafters, and with the permeable membrane
allowing for the transmission of water vapor emanating from the
insulation mat and into the channel.
17. The method of claim 16, further comprising: covering the
insulation mat with the vapor permeable membrane to repel water
from seeping into the insulation mat.
18. The method of claim 16, further comprising: installing the
insulation product in a space between the adjacent rafters that are
supported above a top plate of an exterior wall of a building, with
the channel extending to a space above a ventilated soffit or eave
of the roof and along the space between the adjacent rafters, such
that, the channel maintains a passage for ventilating air to flow
from the ventilated soffit or eave, over the top plate, and along
the space between the adjacent rafters.
19. The method of claim 16, further comprising: assembling the
baffle in between wings of the insulation material.
20. The method of claim 16, further comprising: installing an
interior room ceiling on the rafters, wherein the ceiling
comprises, gypsum board or nailboard or paneling.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 10/996,225 filed Nov. 23, 2004, entitled
"Insulation Batt Having Integral Baffle Vent" (D0932-00490), the
entirety of which is hereby incorporated by reference herein.
[0002] This application is also related to commonly assigned U.S.
patent application Ser. No. 10/666,657 to Richard Duncan and Dustin
Ciepliski, entitled "Baffled Attic Vent Including Method of Making
and Using Same" filed Sep. 19, 2003 (D0932-00389), the entirety of
which is hereby incorporated by reference herein.
FIELD OF THE INVENTION
[0003] The present invention relates to insulation products for
vented air spaces, vented insulation product installations and
methods of installing insulation products for vented air
spaces.
BACKGROUND OF THE INVENTION
[0004] In response to a need for energy conservation, there is a
need for installing thicker insulation batts to reduce both heat
loss in winter and heat gain in summer. Unfortunately, thick
cathedral ceiling insulation tends to obstruct, and even close off,
the ventilation spaces between roof supporting rafters, which can
lead to poor air circulation under the roof.
[0005] Providing ventilation spaces between rafters can also help
reduce the roof deck temperature to lessen damage to the roof deck
and roofing shingles that can result from a build-up of heat to
excessive levels in the summer, as well as, the build up of heat
during the daylight in winter to melt snow and ice, followed by
freezing temperatures that produce ice dams and roof leaks. Roof
ventilation is required by most building codes and by shingle
manufacturers to validate product warranties.
[0006] Quality building construction includes, vented soffits that
are substantially unobstructed by insulation, and vented open
spaces between rafters that are substantially unobstructed by
insulation. Proper ventilation often includes an intake of ambient
air through the soffits, and continuing the passage of the ambient
air along the open spaces between adjacent rafters, to vent or
discharge the build-up of excess humidity, condensation and heat,
the presence of which are known to hasten the deterioration of
roofing materials and structural components.
[0007] Venting moisture adequately from under a roof is
particularly a problem for insulated cathedral ceilings, in which
the roof supporting rafters double, also serve, as the ceiling
joists for supporting the ceiling of an interior space of a
building. Batt-type insulation mats having a sufficient R-value
thickness are customarily inserted between spaced-apart rafters in
cathedral ceilings to insulate the ceilings. Unfortunately, the
thick insulation tends to fill the spaces between the rafters, from
the ceiling below to the roof sheathing above, and thereby, tends
to block ventilating air flow under the roof. Further, although
most fibrous insulation mat have a vapor barrier on their interior
facing surfaces, moisture from inside a building can pass through
open seams and accumulate behind the vapor barrier. Moisture can
also bypass the vapor barrier by traveling along skylights, wiring,
plumbing and HVAC ducts.
[0008] In order to keep cathedral ceiling cavities open, and
thereby provide a channel for air flow, baffled vent chutes have
been installed above the insulation to promote ventilation. Prior
to the present invention, vented cathedral ceilings were often
built in a time consuming two-step application process. The
installer first placed baffled vent chutes to extend between the
rafters, from the eaves to the vented roof ridge, or peak, and
stapled the baffled vent chutes to the roof sheathing that was
exposed between the roof rafters. Then, batt insulation was
installed between the rafters, while the baffled vent chutes held
the insulation away from the under surface of the roof. Each
baffled vent chute created a maintainable open channel for the
passage of ventilating air for venting heat and moisture from the
underside or bottom of the roof sheathing.
[0009] There is a need, therefore, for an insulation product that
reduces installation complexity. Still further, there is a need for
an insulation product that promotes ventilation of a space under a
roof. Still further, there is a need for an insulation product
having an integral baffle and a vapor permeable membrane for
venting moisture into a maintainable channel of the baffle for
ventilating a space between roof supporting rafters.
SUMMARY OF THE INVENTION
[0010] A baffled insulation product for insulating and ventilating
a space between rafters for supporting a roof, is fabricated as an
elongated insulation mat having an integral baffle, at least one
channel on a roof facing side of the baffle for passage of
ventilating air, and at least one vapor permeable membrane covering
at least a portion of the insulation mat facing the channel,
wherein each vapor permeable membrane transmits water vapor
emanating from the insulation mat into said channel.
[0011] The baffled insulation product of the present invention
greatly reduces labor and time associated with installation of a
separate baffle followed by installation of insulation material.
The baffled insulation product promotes ventilation under a roof by
maintaining an open ventilation channel through to the soffit area.
A vapor permeable membrane of the insulation product transmits, and
allows migration of, water vapor emanating from the insulation mat
into the ventilating air stream. The membrane is substantially
impervious to water or ambient condensate or other sources of
liquid water, and covers at least a portion of the insulation mat
to repel liquid water from seeping or percolating therethrough and
wetting the insulation mat. Further, the vapor permeable membrane
transmits, and permits escape of, excess water vapor due to
moisture that builds up in the insulation in the form of increased
relative humidity, due to perceptibly slow water leaks from rain or
plumbing, and further, due to moisture from other sources inside a
building that get behind a vapor retarder facing on the
insulation.
[0012] According to an embodiment of the invention, the vapor
permeability of the vapor permeable membrane increases with
increased relative humidity in the insulation. According to another
embodiment of the invention, the vapor permeable membrane is
substantially impervious to water to prevent the water from seeping
into the insulation mat.
[0013] Weather conditions involving high ambient wind speeds tend
to increase the rate of air exchange between ambient air and
quiescent air among the insulation fibers. The heat transfer rate
due to the air exchange undesirably increases. The vapor-permeable
membrane covers the insulation exposed by the perforated area to
reduce the rate of air exchange.
[0014] The invention further pertains to a method of insulating and
ventilating a space between rafters for supporting a roof,
comprising; (a) assembling an insulation product with an insulation
mat integral with a baffle having at least one open channel
extending the length of the insulation mat, and a vapor permeable
membrane covering at least a portion of the insulation mat that
faces toward the baffle; and (b) installing the insulation product
in a space between adjacent rafters for supporting a roof of a
building, with the channel facing toward an under surface of the
roof for passage of ventilating air along the space between the
adjacent rafters, and with the membrane transmitting water vapor
emanating from the insulation mat and into the channel.
[0015] According to another embodiment of the invention, a method
further comprises, installing the insulation product in a space
between the adjacent rafters that are supported above a top plate
of an exterior wall of a building, with the channel extending to a
space above a ventilated soffit or eave of the roof, such that, the
channel maintains a passage for ventilating air to flow from the
ventilated soffit or eave, over the top plate, and along the space
between the adjacent rafters.
[0016] The above and other features of the present invention will
be better understood from the following detailed description of the
preferred embodiments of the invention that is provided in
connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The accompanying drawings illustrate preferred embodiments
of the invention, by way of example, as well as other information,
in which:
[0018] FIG. 1. is an elevation view in section, of a first
embodiment of an insulation product integral with a foam or sheet
plastic integral baffle;
[0019] FIG. 2 is a partial, top plan view of the embodiment
disclosed by FIG. 1;
[0020] FIG. 3 is an elevation view in section, of a second
embodiment of an insulation product integral with a foam or sheet
plastic integral baffle;
[0021] FIG. 4 is a partial view in section, of a third embodiment
of an insulation product having an integral baffle comprising a
nonwoven ventilation mesh or mafting;
[0022] FIG. 5 is a front perspective view of a fourth embodiment of
an insulation product having a baffle surface formed therein;
[0023] FIG. 6 is a partial side elevation view in section, of the
baffled insulation product of FIG. 1 installed under a roof of a
building structure and over a cathedral ceiling; and
[0024] FIG. 7 is a partial sectional view taken along a line 7-7 in
FIG. 6.
DETAILED DESCRIPTION
[0025] A baffled insulation product for ventilating air under a
roof from an open space is described herein in connection with
FIGS. 1-8. The insulation product has an insulation mat, such as, a
batt, with top and bottom major surfaces, where the top major
surface faces the roof when the product is installed in an open
space, such as, the space between roof supporting rafters of a
cathedral ceiling. The top major surface has a baffle integral or
unitary therewith (e.g., formed therein or coupled thereto)
comprising at least one airflow channel that provides a
continuously open space through which air can easily flow, such as
for allowing or directing the flow of ventilating air under a roof
supported on the rafters.
[0026] FIG. 1 discloses a first embodiment of a baffled insulation
product 10. The baffled insulation product 10 includes an
insulation blanket, mat or batt 12 (hereinafter referred to as mat
12) having top and bottom major surfaces 14, 16, respectively, and
a pair of longitudinal side portions 18 and 20. The top major
surface 14 has a baffle, or baffle section 22 formed integrally
therewith. The baffle 22 forms at least one channel 24 proximate to
the top major surface 14 of the insulation mat 12, allowing for the
passage of ventilating air when the product 10 is installed in an
open space, such as a space between roof supporting rafters. The
rafters further support a cathedral ceiling that is insulated by
the mat 12.
[0027] Insulation materials for forming the mat 12 preferably
comprise any of, light weight, flexible and resiliently
compressible foams or nonwoven fibrous webs or a combination
thereof. Generally, these insulating materials have densities in
the range of about 0.5-7 lb/ft.sup.3 (8-112 kg/m.sup.3), preferably
in the range of about 0.5-6 lb/ft.sup.3 (8-96 kg/m.sup.3), and even
more preferably about 1-4 lb/ft.sup.3 (16-64 kg/m.sup.3). Foam and
nonwoven fibrous web materials are usually provided in continuous
sheeting that can be cut to preselected lengths, thus forming
batts. The thickness of the insulation mat 12 generally corresponds
to the desired insulated effectiveness or "R-value" of the
insulation. These low density insulation mats typically have a
thickness between about 3.5-10 inches and a corresponding R-value
proportional to the thickness.
[0028] Mat 12 is preferably formed from organic fibers such as
polymeric fibers or inorganic fibers such as rotary glass fibers,
textile glass fibers, stonewool (also known as rockwool) or a
combination thereof. Mineral fibers, such as glass, are preferred.
The insulation mat 12 is typically formed from glass fibers, often
bound together with a heat cured binder, such as known resinous
phenolic materials, like phenolfornaldehyde resins or phenol urea
formaldehyde (PUFA). Melamine formaldehyde, acrylic, polyester,
nylon, urethane and furan binder may also be utilized in some
embodiments.
[0029] Baffle 22 can take on any number of shapes, as long as at
least one channel 24 is formed and made integral with the mat 12.
In one embodiment, shown in FIG. 1, the baffle 22 has a generally
squat U-shaped cross section, although other shapes are certainly
contemplated, such as more rounded shapes, such as arcs, or
corrugated shapes that provide more than one channel 24, such as a
generally W-shaped cross-section. In one embodiment, the channel
has a depth of about 1-2''.
[0030] Baffle 22 can comprise several different materials,
including, by way of example, foamed plastic, unfoamed plastic
sheeting, such as PVC (polyvinylchloride) or polypropylene, wood,
sheet metal, and cardboard. A foamed plastic, such as polyurethane,
polyolefin, or polystyrene foam is preferred. An advantage of using
a foamed plastic for baffle 22 is that the foamed plastic can
contribute insulative properties in addition to the R-value of the
product. Suitable flame resistant materials, such as
tris(2,3-dibromopropyl)phosphate, hexabromocyclododecane or
equivalent material, can be added to the base material. The baffle
section 22 can be manufactured by vacuum forming, injection
molding, or a combination of extrusion and a forming step, such as,
belt forming, in which the belt has a mold impression therein,
which forms the shape of the baffle section 22, or by simply
unrolling a sheet material and forming it into the desired
shape.
[0031] In one embodiment, the baffle 22 comprises a radiant heat
reflective top surface facing with an emissivity of less than 0.10,
and preferably less than 0.05, such as an aluminized film, which
faces the roof (i.e., away from the insulation mat 12) when
installed. This aluminized film has an inside surface, facing the
insulation of the mat 12, which serves to reduce the radiant heat
transfer between the baffle 22 and the roof deck or roof sheathing
supported on the rafters, which further support a cathedral
ceiling. In one embodiment, the film is aluminized oriented
polypropylene (OPP). An example of OPP is model MO115821 available
from Dunmore Corp. of Bristol, Pa. The film may also be aluminized
polyester (PET-M), such as available from Phoenix Films Inc. of
Clearwater, Fla. In another embodiment, the reflective facing
comprises a Foil/Scrim/Kraft (FSK) layer, such as model FB30
available from Compac Corporation of Hackettstown, N.J., or an
aluminum foil layer.
[0032] In the embodiment of FIG. 1, the baffle section 22 is
preferably fitted between wing portions 26 of an insulation mat 12,
along the entire length of the mat 12 and is thus, generally
between about 2-10 feet in length. The baffle 22 can be secured by
a friction fit between wings 26, but is more preferably adhered to
the top major surface 14 and/or wings 26 via a melt bond, such as a
hot melt adhesive, or an adhesive, such as, a urethane moisture
cured adhesive or water-based latex adhesive. Alternatively, the
baffle section 22 preferably is between about 1-3 feet in width, in
certain embodiments, to fit between adjacent rafters installed on
centerline spacings of 1-3 feet.
[0033] With reference to FIG. 1, the insulation mat 12 has an open
channel for receiving baffle 22, such channel being formed in the
mat 12 itself. This channel in the mat 12 can be formed by a
manufacturing forming section, or the channel can be cut or
otherwise formed in an already formed insulation mat 12. The baffle
22 is then fitted between longitudinal wing portions 26 of the mat
12. The baffle 22 is preferably secured to the top major surface 14
and/or wings 26 with an adhesive, such as a hot melt adhesive,
urethane moisture cured adhesive or water-based latex adhesive.
Alternatively, the baffle 22 could be mechanically fastened, or
otherwise secured in association with or proximate to the top major
surface 14 of the insulation product 10.
[0034] In some embodiments of the insulation mat 12, such as in
FIG. 1, a vapor retarder facing 28 is provided on a bottom major
surface 16 of the insulation mat 12 to face toward a ceiling to be
insulated above by the insulation mat 12. The vapor retarder 28 is
comprised of a facing layer 29, which may be a cellulosic paper,
typically formed from Kraft paper, coated with a bituminous layer
27, for example, a bituminous adhesive material, such as asphalt,
or a polymeric film, such as low density polyethylene (LDPE). The
facing layer 29 and bituminous layer 27 together form
bitumen-coated Kraft paper 28. The bituminous layer 27 is
preferably applied as a coating in a sufficient amount so as to
provide an effective barrier or retarder for water vapor, for
example, so as to reduce the water vapor permeability of the
preferred Kraft paper to no more than about one perm when tested by
ASTM E96 Method A test procedure. The insulation mats 12 are
installed in spaces between rafters that serve as the ceiling
joists for supporting a cathedral ceiling. An installer staples the
edge margins 29a of the vapor barrier 28 to the rafters to secure
the mats 12 in place. Subsequently, a ceiling 114a, as disclosed by
FIG. 6, is installed, which ceiling 114a covers the installed mats
12 to, and which further support and secure the mats 12 in place.
The ceiling 114a comprises, ceiling panels, such as, nailboard or
gypsum board, or paneling that comprises, for example, sheets of
paneling, or tongue-and-groove interlocked wood boards, are
fastened to the undersides of the rafters, for example, by nails,
staples, glue or other fasteners adapted for the intended
purpose.
[0035] FIG. 2 discloses that the baffle 22, such as, a foam or
unfoamed plastic baffle 22, includes a perforated area having a
plurality of spaced holes 15 extending therethrough for the passage
of water vapor due to a build up of moisture, from minor rain leaks
and moisture laden air from inside a building, which get behind the
vapor retarder 28 and into the insulation mat 12. The moisture is
vented from the insulation mat 12, through the holes 15, through
the baffle 22 and into the ventilating air stream in each channel
24 of the baffle 27. The holes 15 can be of any size and spacing
and can be formed before, during or after affixing the baffle 22 to
the insulation mat 12, according to a desired order of
manufacturing operations. In one embodiment, the holes 15 are
provided through the horizontal bottom wall 21 of the baffle 22.
According to another embodiment, additional holes 15 extend through
the vertical side walls 23.
[0036] In a preferred embodiment disclosed by FIG. 2, the spaced
holes 15 of the perforated area, at least in the bottom wall 21,
are covered by a vapor-permeable membrane 40 or, alternatively, a
smart vapor-permeable membrane 40 also referred to as, a smart
vapor retarder. The membrane 40 can comprise, one or more pieces as
needed to cover the perforated area of the baffle 22. Multiple
pieces are particularly useful to cover different pieces of the
baffle 22 that can be separated from one another along transverse
and/or longitudinal separators 31, described hereinafter.
[0037] The baffled insulation product 10, alternatively, the
baffled insulation product 10A, 10B or 10C, described hereinafter,
may be separable longitudinally down its center, such as described
in, for example, U.S. patent application Ser. No. 10/666,657, US
2005,007,2072A1, incorporated by reference herein. A single
separator feature, such as, a longitudinal separator 31 (FIG. 2)
may be provided as a portion of the baffle 22, such as, a threaded
pull string, score line, weakened area, crease or longitudinal
perforation, which is to be manipulated, such that, the baffle 22
can be split into two pieces or more (e.g., in half). Similarly,
the underlying insulation mat 12 can be perforated longitudinally
or otherwise separable, such as by comprising two or more glued
longitudinal sections. The single separator 31 of the baffle 22 is
aligned with a corresponding perforation or other separator 31 of
the mat 12 so that the insulation product 10 can be split in two
pieces, or in half, preferably tearing the mat 12 by hand, to adapt
the insulation product 10 for installation in narrow spaces or
areas, where the rafters 108 may be spaced closer together. For
example, a preferred insulation product 10 fits between rafters on
24'' centers, which are most common. In this embodiment, the baffle
22 preferably comprises multiple channels 24, so that splitting the
insulation product along its center allows at least one channel 24
to be installed between rafters on 16'' or 12'' centers, which are
less common. The insulation product may also be provided with
transverse separators (not shown). This feature enables the
installer to save materials by using shorter insulation
products.
[0038] In FIG. 2, each membrane 40 comprises, for example, a
continuous strip that is applied lengthwise of the channel 24, and
cut to a desired length. Further, for example, the membrane 40
comprises a continuous strip, with each lengthwise edge margin 40a
comprising an adhesive coating, which leaves a substantial area
between the edge margins 40a, uncovered by the adhesive.
Accordingly, the membrane area without the adhesive will cover a
substantial number of the holes 15. The single membrane 40 or,
alternatively, each multiple membrane 40 can be assembled on the
surface of the baffle 22 to cover respective holes 15. The vapor
permeable membrane 40 covers at least a portion of the insulation
mat 12 that faces toward the baffle 22, such that the membrane 40
transmits water vapor that emanates from the insulation mat 12,
which water vapor is due to excess moisture that builds up in the
insulation mat 12.
[0039] A feature of the invention is disclosed by FIG. 2, wherein,
the membrane 40, or alternatively, each multiple membrane 40, can
be assembled on a roof facing side of the baffle 22. Such a feature
is suitable for retrofitting the baffle 22 with the membrane 40.
According to an alternative feature of the invention, the membrane
40, or alternatively, each multiple membrane 40, can be assembled
on the insulation facing side of the baffle 22, such that the
membrane 40 is between the bottom wall 21 of the baffle 22, and the
top major surface 14 of the mat 12, whereby each membrane 40 is
covered and protected on both sides thereof. According to another
alternative feature of the invention, as taught by FIG. 3, the
single membrane 40, or each multiple membrane 40, can be assembled
directly onto the insulation top major surface 14 of the mat 12
that faces toward the baffle 22, such that when the baffle 22 is
assembled over the top major surface 14 and over the corresponding
membrane 40, the corresponding membrane 40 will cover respective
holes 15 through the baffle 22.
[0040] FIG. 3 discloses an exemplary embodiment in which the vapor
permeable membrane 40 is between the top major surface 14 and the
baffle 22, and extends over a substantial portion of the major
surface 14 of the mat 12. Each lengthwise edge margin 40a of the
membrane 40 can include an adhesive to adhere the substrate to the
surface 14. The area of the membrane 40, between such lengthwise
edge margins 40a, provides a substantial area of both the membrane
40 and a channel 24 provided by the venting mesh 30, which are
uncovered by the adhesive to allow for the movement of air
therethrough, and to vent the air into an open space between roof
supporting rafters where the insulation product is installed. The
baffle 22 can be attached to the top major surface 14 of the
insulation mat 12, or to the membrane 40, or to both the membrane
40 and the top major surface 14 of the insulation mat 12.
[0041] Further, FIG. 3 discloses an alternative embodiment of the
top major surface 14, which is substantially planar (i.e., does not
include a channel cut or otherwise formed therein).
[0042] In an exemplary embodiment, the vapor-permeable membrane 40
comprises a smart vapor-permeable membrane, i.e., a membrane that
changes its moisture vapor permeability with the ambient humidity
condition, such as nylon. In one embodiment, the smart
vapor-permeable membrane is formed from a material such as the
MEMBRAIN.TM. Smart Vapor Retarder available from CertainTeed
Corporation of Valley Forge, Pa. This smart vapor retarder is a
polyamide film, specifically about 99-100% by weight nylon 6, blown
to approximately 2-mil thickness. The film changes its permeability
with the ambient humidity condition. The product's permeance is 1
perm or less when tested in accordance with ASTM E96, dry cup
method, and increases to greater than 10 perms using the wet cup
method. This process allows the baffled insulation product to
increase its drying potential dependent upon the presence of water
inside the mat 12, such as, water from inside a building, due to
water spills, pipe leaks, appliance leaks, or excessive humidity
due to hot water bathing facilities. The vapor permeable membrane
40 reacts to relative humidity by altering pore size, allowing more
or less, regulated amounts of water vapor to pass through it. This
transformation allows drying to occur through the process of vapor
diffusion, thereby improving the speed of drying. The film also
allows other trapped moisture to escape from the insulation mat 12,
thereby limiting odors in the insulation mat typically associated
with mold and bacteria whose growth is encouraged by excess trapped
moisture. Further, the film is advantageous to allow for escape of
moisture from construction materials that have become damp due to
inclement weather and other sources of moisture, before being moved
under a roof of a building that serves as the construction
site.
[0043] Weather conditions involving high ambient wind speeds tend
to increase the rate of air exchange between ambient air and
quiescent air among the insulation fibers. The heat transfer rate
due to the air exchange undesirably increases. The vapor-permeable
membrane 40 covers a portion of the insulation mat 12 that would be
exposed by the perforated area to reduce the rate of air
exchange.
[0044] In yet another alternative embodiment of a baffled
insulation product 10B shown in FIG. 4, the baffled insulation
product 10B includes a non-woven matting or ventilation mesh layer
30 of randomly oriented filaments (such as glass or plastic fibers)
or wires 42 coupled to a substrate 40, which is, in turn, coupled
to the top major surface 14. The matting or ventilating mesh 30
provides the baffle section 22 of porous material for air flow in
horizontal and vertical directions. Further, the matting or
ventilating mesh 30 provides a channel 24 of porous material to
allow for the easy movement of air, specifically the ventilating
air in an open space between roof supporting rafters where the
insulation product 10B is installed. The mat or ventilating mesh 30
also allows for the passage of water vapor emanating from the
insulation mat 12 to enter the ventilating air in the open space
between the roof supporting rafters. Such a feature is advantageous
to allow for escape of moisture from construction materials that
have become damp due to inclement weather and other sources of
moisture, before being moved under a roof of a building that serves
as the construction site. In one embodiment, the substrate material
40 affixed to the top major surface 14 of the mat 12 is air
permeable to permit the free flow of any air when the mat 12 is
compressed, such as during packaging. For example, the substrate
material 40 may include a layer of open nylon or nylon-polyester
matting, in part. Further, the substrate material 40 preferably
comprises a smart vapor-permeable membrane or smart vapor retarder
membrane, to allow moisture to vent from the mat 12 into the
ventilation air stream once installed between rafters.
[0045] The filaments or wires 42 compositely provide a resilient
characteristic. In one embodiment the filaments or wires 42
comprise nylon filaments, a thermoplastic polyamide resin that may
be extruded in situ and heat bonded to the underlying substrate
material 40 at randomly spaced points 41, as taught by U.S. Pat.
No. 4,942,699 to Spinelli, the entirety of which is hereby
incorporated by reference herein. Spinelli '699 teaches that the
convoluted matrix is advantageously formed and bonded to the sheet
material by extrusion of a melted polymer through articulated
spinnerets. One commercial product having a matting or mesh
purportedly manufactured according to Spinelli, U.S. Pat. No.
4,9042,699, is a two-layer composite including a nylon-polyester,
non-woven, non-wicking fabric, heat bonded to a compression
resistant, open nylon matting of three dimensional construction
found on the ROLL VENT.RTM. Continuous Ridge Vent product available
from Benjamin Obdyke of Horsham, Pa. If the non-woven fabric is not
vapor-permeable, it is preferably perforated, such as, by having
holes 15, followed by covering the perforated area comprised of the
holes 15 with the smart vapor permeable membrane 40, in a manner
similarly as described herein with reference to the holes 15
disclosed by FIG. 2. Certainly, other substrates 40 may be used,
such as perforated polyethylene film or non-woven spun-bonded
polypropylene. Further, the ventilation mesh or matting 30 of the
preferred embodiment preferably has a density less than that used
for exterior ridge vents, as it is not intended to form a barrier
to debris and pests as would be the case with a ridge vent,
although the ventilation mesh or matting 30 should have sufficient
rigidity so as to maintain its porosity for providing a porous
ventilation channel 24 once installed between rafters.
[0046] Alternatively, the matting or ventilation mesh 30 can be in
the form of a unitary sheet of randomly aligned synthetic fibers
(e.g., nylon or polyester) that are opened and blended, randomly
aligned into a web by airflow, and joined by phenolic or latex
biding agents and heat cured to produce and air-permeable varying
ventilation mesh. Meshes of this type are taught in U.S. Pat. No.
5,167,579 to Rotter, the entirety of which is hereby incorporated
by reference herein. By "unitary", it is meant that the mat
material is of unitary sheet construction, rather than sheets
laminated or otherwise bonded together. In this embodiment, the
matting or ventilation mesh 30 may be coupled to the remainder of
the insulation product 10A by a strip or strips of adhesive.
Preferably, the matting or ventilation mesh 30 is coupled via
strips of adhesive spaced sufficiently to provide a substantial
area of the matting or ventilation mesh 30 uncovered by the
adhesive, to transmit moisture escaping from the mat 12, through
the vapor permeable membrane 40 and into the ventilating air
stream.
[0047] FIG. 5 is a perspective view of an alternative, baffled
insulation product 10C where the baffle section 22 is formed
directly into the contour of the top major surface 14. In one
embodiment, the baffle section 22 has a corrugated shape formed
into the top major surface 14 along the entire length of the mat
12. The corrugated shape defines an open channel 24 divided into a
plurality of corrugated open channels 24a for ventilating air. The
channel 24 can be formed directly into the major surface 14 by
cutting a portion of the mat 12 from the remainder or main body, or
molding a shape into the mat 12 of the insulation product 10
without assembling a separate baffle section 22. The corrugated
shape shown in FIG. 4 may be formed by, for example, molding the
shape into the mat 12 using a shape former in a binder curing oven
of a manufacturing apparatus, or using a roller to form a permanent
deformation in the mat 12 after the curing oven. Shapes other than
those shown are also appropriate as long as the shape provides
through-ventilation.
[0048] FIG. 5 further discloses an embodiment of the insulation
product 10C having a vapor-permeable membrane 40. The membrane 40
conforms against the corrugated shape of the open channel 24, and
substantially covers the entirety of the major surface 14 of the
mat 12. The membrane 40 is either sufficiently limp and flexible to
conform against the corrugated shape of the open channel 24, or is
sufficiently rigid to retain a corrugated shape that fits against
the corrugated shape of the open channel 24. Each lengthwise edge
margin 40a of the membrane 40 comprises adhesive thereon to adhere
the membrane 40 to the top major surface 14 of the mat 12, and
along the longitudinal side portions 18 and 20 of the mat 12. A
substantial area of the membrane 40, and a substantial area of the
insulation mat 12, are uncovered by the adhesive to allow for the
movement of moisture laden air therethrough, and to vent the air
into an open space between roof supporting rafters where the
insulation product 10C is installed.
[0049] Baffled insulation products 10, 10A, 10B and 10C are
preferably used with sloped or angled ceiling installations, such
as with cathedral ceilings, as shown in, for example, a roof
assembly 100 disclosed in FIG. 6 and in the section view of FIG. 7.
Referring to FIGS. 6 and 7, baffled insulation product 10, by way
of example, is shown in relation to a structure or building 200,
forming the roof assembly 100. Baffled insulation product 10,
alternatively, the baffled insulation product 10A, 10B or 10C, is
positioned to provide a vent passage (shown in shadow outline)
along the open channel 24 extending to a soffit area or space 101
above a soffit that is ventilated at 113, and along the open space
102 between roof supporting rafters of the building 200.
Alternatively, the open channel 24 is defined by the baffle section
22 in either of the embodiments disclosed by FIGS. 1, 3, 4 and 5.
Building 200 can be an industrial or residential building,
including a home, garage, office and like structure. Building 200
has a conventional top wall plate 111 located on top of an upright
exterior wall 110. A generally sloped or angled cathedral ceiling
114a extends from top plate 111 to face downward to an interior of
the building 200. Roof rafters 108 (shown in the cross section of
FIG. 7) extend from, and slope upwardly from, top plate 111, and
support a roof comprised of conventional roofing materials, for
example, sheathing or boards 104 on which roofing material 105 is
installed. Typically, the roofing material 105 includes, an
underlayment of roofing felt covered by overlapping layers of
either asphalt shingles or roll roofing.
[0050] Soffit area or space 101 has a vent 113 for allowing air to
move into the soffit area or space 101 beneath the roof overhang.
Further, the structure has conventional openings or spaces 112
above the top plate 111 and below the roof, such as, for example,
the roof sheathing 104, for passage of ventilating air, indicated
by arrows in FIG. 6, entering as ambient air into vents 113 in the
vented soffit area or space 101. Further, the spaces 112 are
contiguous with the spaces 102 between adjacent roof supporting
rafters 108, for passage of the ventilating air upward between the
rafters 108, until exiting via a conventional, vented roof ridge or
peak (not shown). The baffled insulation product 10, when disposed
below the roof sheathing or boards 104, provides an air passage
space along the channel 24 of the baffle section 22 that extends to
the soffit area or space 101, for the passage of ventilating air to
move along the channel 24 and in the space 102 between adjacent
rafters 108, from soffit area 101, above the top plate 111, and to
the vented roof ridge or peak, not shown. The baffle portion 22 of
the baffled insulation product 10, alternatively, the baffled
insulation product 10A, 10B or 10C, allows insulation to be placed
above ceiling 114a and over and adjacent to top wall plate 111,
without blocking the passage of the ventilating air. The baffle 22
extends over top plate 111 to prevent the insulation mat 12 from
inhibiting the passage of ventilation of air through soffit area
101 and into the space 102 between the rafters 108.
[0051] Baffled insulation product 10 is installed between adjacent
roof rafters 108. The roof rafters 108 are shown in FIG. 7 and are,
for example, 12'', 16'' or 24'' on center. In one embodiment, the
baffle 22 is preferably shaped to have an installed convective air
flow reading under 5 Pa air pressure differential of between about
35-150 CFM @ 5 Pa.
[0052] Further, the invention pertains to a method of insulating
and ventilating a space 102 between rafters 108 for supporting a
roof, comprising the following steps: (a) providing an insulation
product 10, 10A, 10B or 10C having an insulation mat 12 integral
with a baffle 22 having at least one open channel 24 extending the
length of the insulation mat 12, and a vapor permeable membrane 40
covering at least a portion of the insulation mat 12 that faces
toward the baffle 22, and (b) installing the insulation product 10,
10A, 10B or 10C in a corresponding space 102 between adjacent roof
supporting rafters 108 of a building 200, with the channel 24
facing toward an under surface of the roof for passage of
ventilating air along the space 102 between the adjacent rafters
108, and with the membrane 40 transmitting water vapor emanating
from the insulation mat 12 and into the channel 24.
[0053] Further, the method comprises, covering the insulation mat
12 with the vapor permeable membrane 40 to repel liquid or water,
such as, ambient condensate, from seeping into the insulation mat
12.
[0054] Further, the method comprises, installing the insulation
product 10, 10A, 10B or 10C in a space 102 between the adjacent
rafters 108 that are supported above a top plate 111 of an exterior
wall 110 of a building 200, and with the channel 24 extending to a
space 112 above a ventilated soffit 113 or eave of the roof and
extending along the space 102 between the adjacent rafters 108.
Advantageously, when the insulation product 10, 10A, 10B or 10C is
installed to cover the top plate 111, the channel 24 maintains a
passage for ventilating air to flow from a ventilated soffit 113 or
eave, over the top plate 111, and into the space 102 between the
adjacent rafters 108.
[0055] The baffled insulation product 10A, 10B and 10C of the
present invention greatly reduces labor and time associated with
providing ventilated attic spaces. With the baffled insulation
product, no separate operation is required to install the baffle 22
separate from the chosen insulation material. The baffled
insulation product promotes ventilation under a roof and other open
spaces by maintaining an open ventilation channel through to the
soffit area and/or to the roof ridge area. The insulation product
also allows for improved migration of water vapor emanating from
the insulation mat 12 into the ventilating air stream.
[0056] Although the invention has been described in terms of
exemplary embodiments, it is not limited thereto. Rather, the
appended claims should be construed broadly to include other
variants and embodiments of the invention that may be made by those
skilled in the art without departing from the scope and range of
equivalents of the invention.
* * * * *