U.S. patent application number 13/399829 was filed with the patent office on 2012-07-12 for building system with multi-function insulation barrier.
This patent application is currently assigned to JAMES HARDIE TECHNOLOGY LIMITED. Invention is credited to Anthony Milostic.
Application Number | 20120174503 13/399829 |
Document ID | / |
Family ID | 43606476 |
Filed Date | 2012-07-12 |
United States Patent
Application |
20120174503 |
Kind Code |
A1 |
Milostic; Anthony |
July 12, 2012 |
BUILDING SYSTEM WITH MULTI-FUNCTION INSULATION BARRIER
Abstract
The invention relates to a building section including a
sub-structure and a cladding member connected in fixed relation
relative to the sub-structure. A multi-function elongate, flexible
insulating element is disposed between the sub-structure and the
cladding member for damping energy transfer between the cladding
member and the sub-structure, facilitating alignment of the
cladding, and creating a rainscreen configured to drive out
moisture from the wall cavities. In some implementations, the
insulating element has at least one insulating layer which is
substantially incompressible and which has a substantially constant
density in the range of 200 kg/m3 to 300 kg/m3. In certain
preferred implementations, the insulating element can be formed of
a foam material such as foam tape or thermal break tape.
Inventors: |
Milostic; Anthony;
(Rosehill, AU) |
Assignee: |
JAMES HARDIE TECHNOLOGY
LIMITED
Dublin
IE
|
Family ID: |
43606476 |
Appl. No.: |
13/399829 |
Filed: |
February 17, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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PCT/AU2010/001065 |
Aug 20, 2010 |
|
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13399829 |
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Current U.S.
Class: |
52/173.1 ;
52/309.4; 52/480; 52/483.1; 52/741.4 |
Current CPC
Class: |
E04B 2/7409 20130101;
E04B 9/245 20130101; E04B 2/7457 20130101 |
Class at
Publication: |
52/173.1 ;
52/483.1; 52/309.4; 52/480; 52/741.4 |
International
Class: |
E04B 2/44 20060101
E04B002/44; E04B 1/62 20060101 E04B001/62; E04B 1/66 20060101
E04B001/66; E04C 2/20 20060101 E04C002/20 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 20, 2009 |
AU |
2009903931 |
Claims
1. A building system comprising: a building frame comprising a
plurality of studs; an exterior cladding; an interior sheathing; a
plurality of spaced apart elongate multi-function insulative
barriers, each of the insulative barriers is disposed between the
exterior cladding and the interior sheathing and extends along the
length of one of the studs so that each of the insulative barriers
can be fastened to a respective stud, wherein said insulative
barriers together create a clearance space that functions as a
rainscreen between said exterior cladding and said interior
sheathing.
2. The building system of claim 1 wherein the elongate
multi-function insulative barrier comprises a substantially
incompressible foam material.
3. The building system of claim 1 wherein the elongate
multi-function insulative barrier comprises a foam tape.
4. The building system of claim 1 wherein the clearance space
between said exterior cladding and said interior sheathing is
between 5 mm to 50 mm.
5. The building system of claim 1 further comprising a foam
insulative sheathing, said foam insulative sheathing is disposed
adjacent said interior sheathing.
6. The building system of claim 1 wherein the elongate
multi-function insulative barrier comprises indicia configured to
facilitate alignment of said exterior cladding.
7. A building section comprising: a sub-structure; a cladding
member connected in fixed relation relative to the sub-structure;
and an elongate, flexible, insulating element, the insulating
element having at least one insulating layer which is substantially
incompressible and which has a substantially constant density in
the range of 200 kg/m3 to 300 kg/m3, wherein the insulating element
is disposed between the sub-structure and the cladding member for
damping energy transfer between the cladding member and the
sub-structure.
8. A building section according to claim 7, wherein the insulating
element is a composite element having two or more layers with a
first layer being the at least one substantially incompressible
insulating layer and a second layer being more deformable than the
substantially incompressible insulating layer so as to readily
adapt to irregularities in the cladding and/or building
structure.
9. A building section according to claim 7, wherein the at least
one substantially incompressible layer of the insulating element
has a hardness of at least 60 HC.degree..
10. A building section according to claim 7, wherein the at least
one substantially incompressible layer of the insulating element
has a compressive strength in the range of approximately 200 kPa to
400 kPa.
11. A building section according to claim 7, wherein the at least
one substantially incompressible layer of the insulating element
has a thermal conductivity of less than 0.1 W/mK.
12. A building section according to claim 7, wherein the at least
one substantially incompressible layer of the insulating element is
configured to have a thermal resistance of at least 0.1
Km.sup.2/W.
13. A building section according to claim 7, wherein the thickness
of the insulating element is in the range of about 5 mm to 50
mm.
14. A building section according to claim 7, wherein the insulating
element has a plurality of markings, the markings being spaced
relative to one another on an outer surface of the insulating
element for facilitating alignment of the cladding members relative
to the sub-structure.
15. A building section according to claim 7, wherein the insulating
element is formed of foam.
16. A building section according to claim 7, wherein the
sub-structure includes an intermediate support member connected to
a frame member, the support member being arranged intermediate the
frame member and the cladding member such that the insulating
element is sandwiched between the frame member and the support
member or between the support member and the cladding member.
17. A building section according to claim 16, wherein the
intermediate support member is a top-hat batten, the top-hat batten
having a base, two webs extending from the base and a flange
associated with the distal end of each web.
18. A building section according to claim 7, wherein the width of
the insulating element is less than or equal to the width of the
associated frame member to which it is attached.
19. A method of constructing a building section, the method
comprising: erecting a sub-structure; connecting a cladding member
in fixed relation relative to the sub-structure; and arranging an
elongate, flexible insulating element between the sub-structure and
the cladding member for damping energy transfer between the
cladding member and the sub-structure, the insulating element
having at least one insulating layer which is substantially
incompressible and which has a substantially constant density in
the range of 200 kg/m3 to 300 kg/m3, wherein the insulating element
is disposed between the sub-structure and the cladding member for
damping energy transfer between the cladding member and the
sub-structure and for creating a rainscreen to inhibit moisture
from entering the sub-structure.
20. The method according to claim 19 wherein arranging an elongate,
flexible insulating element comprises applying a plurality of
spaced apart foam strips between the cladding member and the
sub-structure.
Description
REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of PCT
Application Number PCT/AU2010/001065 filed Aug. 20, 2010 which
claims priority to Australian Patent No. 2009903931 filed Aug. 20,
2009 which are hereby incorporated by reference in their entirety
herein.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of
building systems and, in particular, to systems incorporating the
use of improved materials and construction techniques for
insulating, facilitating alignment, and/or providing a rainscreen
for a section of a building.
[0003] The invention has been developed specifically for use in
connection with internal and external cladding systems and will be
described primarily with reference to this application.
BACKGROUND OF THE INVENTION
[0004] The following discussion of the prior art is intended to
enable the invention to be placed in an appropriate technical
context and to allow the advantages of it to be fully appreciated.
However, any discussion of the prior art throughout the
specification should in no way be considered as an admission that
such prior art is widely known or forms part of common general
knowledge in the field.
[0005] With the advent of new and improved cladding materials in a
variety of geometrical forms, the popularity of frame plus cladding
construction techniques is increasing, particularly in the
residential market. At the same time there is increasing demand for
energy efficient structures which necessitates, or at least
encourages, use of insulating materials between the frame and the
cladding of such structures. Furthermore, in most cladding systems,
a space is maintained between the exterior wall panels and interior
insulation layer to serve as a rainscreen. The rainscreen deters
rainwater intrusion into the building and allows ventilation and
removal of any water that may enter the wall cavity.
[0006] One difficulty which arises in constructing some cladding
systems, is the need to correctly align the mating surfaces of
adjacent cladding panels on the frame, and to maintain this
alignment after the erection process has been completed. In a
cladding system for a wall, it is typically desired to fix the
cladding panels to the frame such that a substantially continuous
wall surface is defined by each array of panels, be they flat
mounted panels or long arrays of panels to be mounted in an
overlapping arrangement. However, using popular soft foam thermal
insulating strips for example, it is often difficult to achieve
such a flat surface at the adjoining or abutting edges of adjacent
panels, which reduces the aesthetic appeal provided by the final
wall. This difficulty arises, at least in part, due to the physical
properties of these soft foam insulating strips and/or
irregularities in the frame.
[0007] Such misalignment of adjacent cladding panels can give rise
to a more serious situation where the building section is a floor
of the building. In particular, such misalignment of adjacent
panels or floor boards can give rise to undesirable unevenness in
flooring. While rigid polystyrene foam alternatives used for walls
and high density rubber sheets used for floors reduce this problem
to some extent, they are slow to install and awkward to
transport.
[0008] Another issue which arises with the use of soft foam strips
is that, when either hand or gun nailing the cladding panels to the
frame, the nails are often over driven such that an indentation is
formed in the cladding panel and the head of the nail sits beneath
the surface of the panel, again reducing the aesthetic appeal
provided by the wall.
[0009] It is an object of the present invention to overcome or
ameliorate one or more of the disadvantages of the prior art, or to
at least provide a useful alternative.
SUMMARY OF THE INVENTION
[0010] Various embodiments of the present invention provide
building systems that incorporate multi-function insulative
barriers adapted to provide insulation, facilitate cladding
alignment, and form a rainscreen to drive out moisture. In certain
preferred embodiments, the building system includes a building
frame having a plurality of studs, an exterior cladding, an
interior sheathing, and a plurality of spaced apart elongate
multi-functional insulative barriers. Each of the insulative
barriers is disposed between the exterior cladding and the interior
sheathing and extends along the length of one of the studs so that
each of the insulative barriers can be fastened to a respective
stud. The insulative barriers together create a clearance space
that functions as a rainscreen between the exterior cladding and
the interior sheathing. In some embodiments, the insulative barrier
further includes indicia configured to facilitate alignment of the
exterior cladding during installation. The insulative barriers can
be made of a foam material such as foam tape or thermal back tape.
In one implementation, the insulative barriers are made of a
substantially incompressible foam material. In another
implementation, the building system further includes a foam
insulative sheathing disposed adjacent the interior sheathing. In
yet another implementation, a weather resistant barrier layer can
be applied to the interior sheathing as well.
[0011] According to another embodiment of the invention, there is
provided a building section including:
[0012] a sub-structure;
[0013] a cladding member connected in fixed relation relative to
the sub-structure; and
[0014] an elongate, flexible insulating element, the insulating
element having at least one insulating layer which is substantially
incompressible and which has a substantially constant density in
the range of 200 kg/m3 to 300 kg/m3, wherein the insulating element
is disposed between the sub-structure and the cladding member for
damping energy transfer between the cladding member and the
sub-structure.
[0015] The term "substantially incompressible" is used herein to
define at least one insulating layer of an insulating element which
substantially resists compression during and after fixing between a
sub-structure and a cladding member when conventional fasteners are
used to secure the cladding member to the sub-structure with the
insulating element therebetween.
[0016] The term "cladding member" is intended to include all
internal or external wall, floor and ceiling covering panels and
planks or opening covers such as windows and door frames, as may be
secured to a structural frame to define a building envelope.
[0017] The substantially incompressible characteristic of the at
least one insulating layer results in this layer substantially
maintaining its geometric shape when the cladding member is being
connected to the sub-structure by fasteners which pass through the
insulating element. Desirably, the at least one insulating layer
provides support to the cladding member when the cladding member is
being secured to the sub-structure. It will be appreciated that
this enables cladding materials such as fiber cement panels to be
nailed or screwed to the sub-structure using conventional power
tools and the like by providing rear support to the material.
Advantageously, the substantial incompressibility of the at least
one insulating layer helps facilitate the erection of a building
section having a substantially continuous cladding surface at the
abutting edges of adjacent cladding members. The substantial
incompressibility of the at least one insulating layer also helps
to inhibit over driving fasteners when using conventional hand and
power tools.
[0018] In certain preferred embodiments, the insulating element
reduces the transfer of thermal energy between the cladding member
and the sub-structure. In other preferred embodiments, the
insulating element reduces the transfer of acoustic energy between
the cladding member and the sub-structure. Preferably, the
insulating element reduces the transfer of both thermal and
acoustic energy between the cladding member and the sub-structure.
In some embodiments, the damping of energy transfer between the
cladding member and the sub-structure is primarily effected by the
at least one substantially incompressible insulating layer. In
other embodiments, the damping of energy transfer is achieved by
the combination of the substantially incompressible insulating
layer or layers and the remaining layer or layers of the insulating
element. That is, in these embodiments, the damping of energy
transfer is achieved by the insulating element as a whole.
[0019] The cladding member is preferably connected to the
sub-structure via one or more fasteners. Preferably, the one or
more fasteners securely engage the sub-structure and the cladding
member. At least certain of the one or more fasteners preferably
pass through the insulating element to hold the insulating element
in a desired position relative to the cladding
member/sub-structure. The fasteners are preferably selected from
the group including nails, screws, staples and rivets. However, it
will be appreciated by those skilled in the art that the fasteners
are not limited to those listed here, and that any suitable
fastener (including adhesives) may be used to connect the cladding
member to the sub-structure.
[0020] The at least one insulating layer is preferably formed of a
foam, more preferably, a closed cell foam such as, for example,
polyolefin. In some preferred forms, the foam is cross-linked.
Suitable cross-linked foams include polyurethane and polystyrene.
It will of course be appreciated that the closed cell and
cross-linked foams are not limited to those listed here, and that
other suitable foams may be used.
[0021] In addition, it will also be appreciated that the insulating
element may, in certain preferred forms, be a homogeneous element
such that the overall construction results in a flexible,
substantially incompressible insulating element.
[0022] However, in other preferred embodiments, the insulating
element may be a hybrid or composite element having two or more
layers, at least one layer being formed of a material having at
least one different physical property relative to the material used
to form one or more of the other layers. For example, the
insulating element may be a two-layer element having one layer
which is relatively `harder` than the other. Alternatively, the
insulating element may be a three-layer element in which the outer
layers are relatively `harder` than the inner layer, or vice versa.
In such embodiments, the first `harder` layer or layers are
substantially incompressible and the second `softer` layer or
layers can advantageously deform to account for, or at least reduce
the effect of, irregularities in the sub-structure to provide a
substantially flat surface across adjacent cladding panels.
Accordingly, in embodiments having a `softer` outer layer, this
layer preferably abuts the sub-structure. However, in other
embodiments the softer outer layer could abut the cladding member
or another intermediate member.
[0023] It will of course be appreciated that the insulating element
could be embodied in many various differently layered constructions
to suit a particular building application.
[0024] For multi-layered embodiments of the insulating element, one
or more of the physical properties of density, hardness,
compressive strength, thermal conductivity, thermal resistance,
cross-section and thickness of at least one layer may be configured
to be different to that of another layer of the insulating element.
It will be appreciated by those skilled in the art that the
physical properties which can be varied are not limited to those
listed here.
[0025] In some embodiments of the insulating element having two or
more layers, the thickness of each layer is substantially the same.
In other embodiments, the thickness of each layer is different
relative to each other.
[0026] Preferably, the flexibility of the insulating element
enables the insulating element to be wound along its longitudinal
axis to form a (spiralled) roll of the insulating element for
storage prior to use.
[0027] In other embodiments, the insulating element can be supplied
as substantially flat strips or "sticks" of a predetermined length.
The predetermined length may be suitable for immediate use of the
insulating element or for the insulating element to be readily
cut-to-length, as desired. In some embodiments, the sticks of the
insulating element have a length of approximately 3 m. It will
however be appreciated by those skilled in the art that the sticks
can be supplied in any desired length, including lengths longer and
shorter than 3 m. For example, the insulating element could be
supplied in lengths of, but not limited to, 1.0 m, 1.2 m, 1.5 m,
1.8 m, 2.0 m, 2.4 m, 2.5 m, 2.75 m, 3.5 m, 4 m, 4.5 m, 5.0 m or 6.0
m.
[0028] Preferably, the density of the substantially incompressible
insulating layer is in the range of about 205 kg/m.sup.3 to 255
kg/m.sup.3. In one particularly preferred embodiment, the density
of the insulating layer is approximately 230 kg/m.sup.3. In another
particularly preferred embodiment, the density of the insulating
layer is approximately 300 kg/m.sup.3. It will be appreciated that
the density of the insulating element is not limited to the values
listed here, but rather will be selected to meet the insulating
requirements of a particular application.
[0029] Preferably the insulating element (or at least one layer of
the insulating element) has a hardness at least 60 HC.degree., as
measured under the Durometer Type C hardness standard specified in
ASTM D2240. In various other embodiments, the insulating element
(or at least one layer of the insulating element) may have a
hardness of at least 80 HC.degree., at least 100 HC.degree. or at
least 200 HC.degree..
[0030] The insulating element (or the at least one insulating
segment) preferably has a compressive strength in the range of
approximately 200 to 400 kPa.
[0031] The insulating element (or the at least one substantially
incompressible insulating layer) preferably has a constant
thickness. Those skilled in the art will appreciate that the
constant thickness of the insulating element (or the at least one
insulating layer) in combination with the substantially
incompressible property helps to fix and maintain adjacent cladding
members relative to the sub-structure such that abutting edges are
not raised or lowered relative to each other but, rather are
substantially flush with each other.
[0032] Preferably, the insulating element (or the at least one
insulating layer) has a thermal conductivity of less than 0.1 W/mK.
In certain preferred embodiments, the insulating element (or the at
least one insulating layer) has a thermal conductivity of less than
0.06 W/mK. In one particularly preferred embodiment, the insulating
element (or the at least one insulating layer) has a thermal
conductivity of approximately 0.035 W/mK.
[0033] Preferably, the insulating element (or the at least one
insulating layer) is configured to have a thermal resistance, or
R-value, of at least 0.1 Km.sup.2/W, more preferably, at least 0.2
Km.sup.2/W. It will of course be appreciated that in other forms,
the building section as a whole will be constructed to have a
particular R-value to meet the building code of a particular
jurisdiction. For example, in Australia the building section may be
required to have an R-value of at least 0.2 Km.sup.2/W. In New
Zealand, the building section may be required to have an R-value of
at least 0.3 Km.sup.2/W.
[0034] In certain preferred embodiments having a predetermined
cross-section of constant width, the thermal resistance is
determined by the thickness of the insulating element(or the at
least one insulating layer). The thickness of the insulating
element (or the at least one insulating layer) is preferably in the
range of about 5 mm to 50 mm. More preferably, the thickness of the
insulating element (or the at least one insulating segment) is in
the range of about 5 mm to 30 mm. In particularly preferred forms,
the thickness of the insulating element (or the at least one
insulating layer) is in the range of about 6 mm to 20 mm, with even
more preferred forms in the range of 7 mm to 13 mm. In one
particularly preferred form, the thickness of the insulating
element (or the at least one insulating layer) is approximately 13
mm. In another particularly preferred form, the thickness of the
insulating element (or the at least one insulating layer) is
approximately 7.5 mm.
[0035] Preferably, the insulating element (or the at least one
insulating layer) defines a mounting surface for abutting one of
the sub-structure and the cladding member. The insulating element
(or the at least one insulating layer) preferably includes an
attaching means associated with the mounting surface for attaching
the insulating element in position. In certain embodiments, the
attaching means is used to attach the insulating element to the
cladding member. In other embodiments, the attaching means is used
to attach the insulating element to the sub-structure. Preferably,
the attaching means is a layer of adhesive applied to the mounting
surface of the insulating element(or the at least one insulating
layer). Preferably, the adhesive is acrylic. In certain preferred
forms, a layer of adhesive may also be applied to a surface of the
insulating element (or the at least one insulating layer) which is
opposite the mounting surface (i.e. the operative outer
surface).
[0036] It will be appreciated that the adhesive layer on the
mounting surface provides the insulating element with the
characteristic of a self-adhesive tape and thus facilitates
installing the insulating element in the desired position.
[0037] In those embodiments in which a layer of adhesive is also
applied to the opposite surface to that of the mounting surface,
this additional layer of adhesive can be used to hold the cladding
members in a desired position relative to the sub-structure (or at
least take some of their weight) to facilitate driving fasteners
through the cladding members.
[0038] In embodiments in which certain fasteners pass through the
insulating element, the adhesive layer works in combination with
these fasteners to secure the insulating element relative to the
cladding member/sub-structure.
[0039] In certain preferred forms, the insulating element has a
plurality of markings or indicia, the markings being spaced
relative to one another on the operative outer surface of the
insulating element for facilitating alignment of the cladding
members relative to the sub-structure. That is, the markings act as
a depth gauge during construction of the building section.
Preferably, the markings are configured such that when a top edge
of a cladding member is aligned with a marking it follows that the
cladding member is correctly aligned relative to the sub-structure,
in use. In some forms, the markings are spaced relative to one
another to suit a cladding member of a particular size or shape. In
other forms, the insulating element can have two or more sets of
markings, each set being configured to facilitate alignment of
cladding members of a particular size or shape. For example, the
insulating element could have three sets of markings including a
first set for plank-style cladding members, a second set for
sheet-style cladding members and a third set for board-style
cladding members. It will be appreciated that pairs of insulating
elements with corresponding markings are preferably used to
facilitate the alignment of the cladding members. That is, a first
insulating element is applied to a first member of the
sub-structure and a second insulating element is applied to a
second member of the sub-structure whereby the top edge of the
cladding member can be aligned with a marking on the first
insulating element and a corresponding marking on the second
insulating element so that the cladding member is correctly aligned
relative to the sub-structure.
[0040] Preferably, the sub-structure is a frame having a plurality
of frame members. The frame is preferably one of a wall frame, a
sub-floor frame, a ceiling frame (including eaves) and a roof
frame. However, it will be appreciated by those skilled in the art
that the present invention is not limited to the sub-structures
listed here.
[0041] In certain embodiments, each frame member is formed of
metal. Preferably, the metal is steel. In other embodiments, the
metal is aluminum. In other preferred embodiments, the frame
members are formed of timber.
[0042] In some preferred embodiments, the insulating element is
close-fittingly disposed between the sub-structure and the cladding
member. In other embodiments, the sub-structure includes an
intermediate support member connected to a frame member, the
support member being arranged intermediate the frame member and the
cladding member such that the insulating element is sandwiched
between the frame member and the support member or between the
support member and the cladding member. In certain embodiments, a
first insulating element is provided between the frame member and
the support member and a second insulating element is provided
between the support member and the cladding member.
[0043] The intermediate support member is preferably a top-hat
batten, the top-hat batten having a base, two webs extending from
the base and a flange associated with the distal end of each web.
Preferably, an insulating element is associated with the base and
each flange.
[0044] It will be appreciate that, in those embodiments in which
the frame is a sub-floor frame, the insulating element primarily
provides acoustic insulation. Similarly, it will also be
appreciated that in those embodiments in which the frame is a wall
or ceiling frame, the insulating element is usually selected
primarily to provide thermal insulation.
[0045] Preferably, the insulating element is attached to one of the
frame members of the sub-structure. More preferably, the insulating
element is attached to the frame member by the adhesive. The
insulating element preferably extends in a direction substantially
parallel to the longitudinal direction of the respective frame
member. Preferably, an insulating element is attached to one or
more of the substantially vertical frame members of the
sub-structure. In some embodiments, an insulating element is
attached to each substantially vertical frame member. In certain
embodiments, an insulating element is also applied to at least one
of the substantially horizontal frame members.
[0046] The width of the insulating element (or the at least one
insulating layer) may be greater than or less than the width of the
associated frame member to which it is attached. In certain
embodiments, the width of the insulating element (or the at least
one insulating layer) is substantially the same as the width of the
associated frame member. In the event that double-framing is used,
an insulating element may be applied to each frame member.
[0047] Preferably, the cladding member is a cladding panel, the
cladding panel defining a cladding surface for the building
section. It will be appreciated that the cladding member can be an
internal cladding member or an external cladding member. More
particularly, the cladding member may be internal or external wall
sheeting, a ceiling sheet or floor boards. It will also be
appreciated that the cladding member can be formed of any suitable
cladding material and is preferably formed of one of fiber cement,
polystyrene, timber, gypsum board and metal.
[0048] Preferably, the building system includes sarking for
inhibiting the passage of liquid through the building section, the
sarking being arranged between the sub-structure and the cladding
member. In some preferred embodiments, the sarking is arranged to
be between the sub-structure and the insulating element. In other
preferred embodiments, the sarking is arranged to be between the
insulating element and the cladding member. The sarking is
preferably a membrane of flexible, vapor permeable material. In
various embodiments, some of the one or more fasteners are used to
secure the sarking in place relative to the cladding member. In
other embodiments, a separate fastening means is used to secure the
sarking in place. The building section may also include some form
of rigid air barrier lining.
[0049] It will be appreciated that when strips of the insulating
element are applied to the sub-structure, the cladding members will
be spaced from the sub-structure such that a cavity or void is
formed between the cladding member and the plane on which the
mounting surface of the insulating element lies. In certain
embodiments, the cavity or void improves the overall efficiency of
the insulation associated with the building section by improving
the R-value of the building section and/or acts as a rainscreen or
drainage passage through which rainwater may pass or evaporate so
that this water is not trapped inside the building section. That
is, the cavity or void facilitates moisture management within the
building section and thus reduces or delays the onset of water
damage, advantageously improving the durability of the building
section. The thickness of the cavity or void is preferably at least
6 mm. When the thickness of the cavity is 6 mm or greater, the
benefit of the moisture management characteristic is most
noticeable.
[0050] According to yet another embodiment of the invention, there
is provided a method of constructing a building section, the method
including:
[0051] erecting a sub-structure;
[0052] connecting a cladding member in fixed relation relative to
the sub-structure; and
[0053] arranging an elongate, flexible insulating element between
the sub-structure and the cladding member for damping energy
transfer between the cladding member and the sub-structure, the
insulating element having at least one insulating layer which is
substantially incompressible and which has a substantially constant
density in the range of 200 kg/m3 to 300 kg/m3, wherein the
insulating element is disposed between the sub-structure and the
cladding member for damping energy transfer between the cladding
member and the sub-structure.
[0054] In some embodiments, the body of the insulating element is a
homogenous construction. In other embodiments, the body of the
insulating element is a multi-layered construction. In layered
embodiments of the insulating element the body at least one layer
is formed of a material having at least one different physical
property relative to the material used to form one or more of the
other layer or layers. The use of multi-layered insulating elements
advantageously enables an insulating element to be constructed so
as to be suitable for use with particular cladding and framing
materials, to account for irregularities in the cladding and/or
framing materials, to account for expected environmental conditions
and/or to suit the method of construction used for erecting the
building section.
BRIEF DESCRIPTION OF THE DRAWINGS
[0055] A preferred embodiment of the invention will now be
described, by way of example only, with reference to the
accompanying drawings in which:--
[0056] FIG. 1 is a schematic front view of a building section
according to the invention;
[0057] FIG. 2 is a plan view of the building section of FIG. 1;
[0058] FIG. 3 is a plan view of another embodiment of the building
section;
[0059] FIG. 4 is a front view of an embodiment of a frame of the
building section;
[0060] FIG. 5 is a schematic side view of a roll the insulating
element of the building section;
[0061] FIG. 6 is a partial perspective view of the insulating
element showing the layer of adhesive on the mounting surface;
[0062] FIG. 7 is a schematic illustration of one embodiment of a
wall assembly with multi-function insulative barriers; and
[0063] FIG. 8 is a schematic illustration of another embodiment of
a wall assembly with multi-function insulative barriers.
PREFERRED EMBODIMENT OF THE INVENTION
[0064] Referring to the drawings, the building section 1 includes a
sub-structure in the form of a frame 2. The frame 2 is formed from
a series of interconnected frame members 3 including a plurality of
substantially vertical frame members and a plurality of
substantially horizontal frame members. As will be described in
greater detail below, the frame members 3 may be made from timber
or metal such as steel.
[0065] For the sake of clarity, the following description will be
made with reference to a wall frame. However, those skilled in the
art will appreciate that the frame 2 may be a section of any
suitable building frame including a wall frame, a sub-floor frame,
a ceiling frame and a roof frame. It will be further appreciated by
those skilled in the art that the present invention is not limited
to the sub-structures listed here. In addition, it is to be
understood that certain frames may be inclined, rather than being
arranged to lie in a substantially vertical or horizontal
plane.
[0066] As most clearly shown in FIG. 1, a plurality of cladding
members in the form of fiber cement cladding panels 4 are connected
in fixed relation relative to the frame 2 by fasteners 5. As will
be described in greater detail below, the plurality of cladding
panels 4 form a cladding or wall surface 6, such as exterior wall
surface, for the building section 1. To facilitate connection of
the panels 4 to the frame 2 of the wall section, each cladding
panel 4 preferably spans two or more of the frame members 3.
[0067] The type of fasteners 5 used to secure the panels 4 to the
frame 2 will be primarily determined by the type of material of the
frame members 3. That is, fasteners 5 in the form of screws, nails
or staples can be used to securely fasten the cladding panels 4 to
a timber frame. However, to fasten the panels 4 to a metal frame,
it may be necessary to employ screws or rivets. Another factor
determining the type of fastener that can be used is the material
of the cladding panels. Again, as will be described in detail
below, the present invention advantageously enables cladding
materials, such as the fiber cement panels 4, to be readily nailed
or screwed to the frame 2 using conventional power tools and the
like.
[0068] In order to provide thermal and/or acoustic insulation to
the wall section 1, an elongate, flexible insulating element in the
form of a foam tape 7 is arranged along the length of at least some
of the substantially vertical frame members 3. As discussed in
greater detail below, in some implementations, the elongate,
flexible insulating element is configured to create a space between
the frame member 3 and panels 4. The space serves as an effective
rainscreen that inhibits water intrusion in the wall cavity.
[0069] For the sake of clarity, the following description will be
made with reference to a homogenous substantially incompressible
insulating element. However, it will be readily appreciated that
the insulating element is not limited to such forms and can
advantageously be embodied as a hybrid or composite construction
having primary layers formed of a substantially incompressible
insulating material and second layers formed a material which can
deform to account for irregularities in the sub-structure or
cladding materials.
[0070] The insulating foam tape 7 is applied in strips and
positioned to extend in a direction substantially parallel to the
longitudinal axis of the associated frame member 3. In the
embodiment illustrated in FIG. 2, a strip of foam tape 7 is applied
to each vertical frame member 3. However, it will be appreciated
that in certain embodiments, it may be sufficient to apply strips
of foam tape 7 to only a selected few of the vertical frame members
3. In yet further embodiments such as that shown in FIG. 4, a strip
of foam tape 7 can be applied to each vertical and horizontal frame
member 3.
[0071] As most clearly shown in FIG. 2, the foam tape 7 has a
rectangular cross-section with a constant thickness along the
length of the strip. The insulating foam tape 7 defines a mounting
surface 8 on which an attaching means in the form of a layer of
acrylic adhesive 9 is applied. The adhesive 9 enables the foam tape
7 to be readily adhered to the relevant frame member 3 in the
desired position. It will therefore be appreciated that the
adhesive layer 9 provides the foam tape 7 with the characteristic
of a self-adhesive tape. In some embodiments, a removable backing
strip (not shown) covers the mounting surface 8 to protect the
layer of adhesive 9 from dust and other debris during storage of
the foam tape 7 prior to use.
[0072] The insulating tape 7 is preferably formed of a closed cell,
cross-linked foam such as, for example, polyolefin. The insulating
element is substantially incompressible such that the insulating
element substantially maintains its geometric shape when the
cladding member is being fastened to the frame. This property
enables the insulating element to provide support to the cladding
material when the cladding member is being secured to the
sub-structure.
[0073] It will be appreciated that it is this property of
substantially incompressibility which enables relatively brittle
cladding materials to be nailed or screwed to the frame 2 using
power tools and the like. For example, a nail-gun can conveniently
be employed to efficiently fasten the panels 4 to the frame 2,
without significant variations in the level or degree of
compression of the foam tape 7 at the various locations at which
the fasteners have been placed.
[0074] The significant lack of compression of the foam tape 7 in
combination with the degree to which this compression is consistent
at the various fastening locations is particularly advantageous at
the adjoining/abutting edges of adjacent cladding panels 4. That
is, the substantial incompressibility of the foam tape 7
facilitates the erection of a building section 1 having a
substantially flush wall surface 6 at the abutting edges of
adjacent cladding panels. In other words, the adjoining or abutting
edges are not significantly raised or lowered relative to each
other as a result of the fastening process. To achieve the required
degree of incompressibility, the polyolefin preferably has a
substantially constant density of about 230 kg/m.sup.3.+-.10%.
[0075] In the form shown in the drawings, the width of the foam
tape 7 is less than that of the associated frame member to which it
is attached. In the illustrated embodiments, the width of the foam
tape 7 is approximately 45 mm. The thickness of the foam tape is
approximately 13 mm.+-.0.16 mm. It will be appreciated that the
tape may be formed in various widths with the thickness of the tape
then being selected to provide the insulating tape with a thermal
resistance of at least 0.2 Km.sup.2/W (or a thermal conductivity of
<0.06 W/mK).
[0076] Each strip of foam tape 7 is adhered directly to the
respective frame member 3 by the layer of adhesive 9. A fiber
cement cladding panel 4 is then held in position relative to the
frame 2, against the foam tape 7. The panel 4 is then secured in
the desired position such that each strip of foam tape 7 is
disposed between the frame 2 and the associated panel 4. As clearly
shown in FIG. 2, at least some of the fasteners 5 pass through the
foam tape 7. The adhesive 9 works in combination with these
fasteners to securely hold the strip of foam tape 7 relative to the
cladding member 4 and frame 2.
[0077] In the cladded wall section 1 shown in the drawings, the
foam tape 7 forms a thermal break for damping thermal transfer
between the cladding panels 4 and the frame 2 to reduce thermal
losses through the wall section 1.
[0078] It will be appreciated that in those embodiments in which
the frame is a roof or ceiling frame, the insulating element again
primarily provides thermal insulation. However, in those
embodiments in which the frame is a sub-floor frame, the insulating
element primarily provides acoustic insulation. In certain
applications, including those listed above, the foam tape can
provide both thermal and acoustic insulation for the building
section 1 and therefore reduce energy losses.
[0079] It will be further appreciated that the foam tape 7 may also
provide a degree of moisture management for the building section.
As shown in FIG. 2, the foam tape 7 is configured to create a
clearance space 15 between the frame member 3 and the associated
panel 4. In some implementations, the clearance space 15 is
configured to resist rain water ingress and may be vented at the
bottom to prevent ingress wind forced rain. Thus, the foam tape 7
effectively serves to create a rainscreen to allow ventilation and
removal of any water that may enter the wall cavity.
[0080] In some preferred embodiments, as illustrated in FIG. 2, the
foam tape 4 is close-fittingly disposed between the frame 2 and the
cladding panel 4. In other embodiments, as shown in FIG. 3, the
frame 2 includes an elongate intermediate support member in the
form of a top-hat batten 10. The top-hat batten 10 has a base 11,
two webs 12 extending from the base 11 and a flange 13 associated
with the distal end of each web 12.
[0081] Again referring to FIG. 3, the top-hat batten 10 is arranged
to extend substantially parallel to a vertical frame member 3 such
that the base 11 overlies the associated frame member 3. In this
embodiment, the base 11 of the top-hat batten 10 is securely
fastened to the associated frame member 3 and the cladding panel 4
is fastened to the webs 12 of the top-hat batten 10. A strip of
foam tape 7 is sandwiched between the frame member 3 and the base
11 of the top-hat batten 10. A strip of foam tape 7 is also
sandwiched between each web 12 and the cladding panel 4. In this
embodiment, the three strips of foam tape 7 act in combination to
provide the desired insulation for damping energy transfer through
the building section 1.
[0082] In other embodiments, a strip of foam tape 7 may be disposed
between the base 11 and the associated frame member 3 only, with no
foam tape being applied between the webs and the cladding panel
4.
[0083] Referring now to FIG. 5, it can be seen that the flexibility
of the insulating foam tape 7 advantageously enables the tape to be
wound along its longitudinal axis to form a spiralled roll 14 of
the self-adhesive insulating tape 7 for storage prior to use. It
will be appreciated that such a roll 14 of self-adhesive insulating
tape 7 is compact, convenient to store and easily handled during
installation as a thermal break.
[0084] Accordingly, it is an advantage of at least a preferred
embodiment of the invention to provide a building section 1 having
an elongate, flexible insulating element which enables adjacent
cladding panels to lie in substantially the same plane such that
the edges of adjacent panels are not raised relative to one
another.
[0085] It is another advantage of at least a preferred embodiment
of the invention to provide an elongate, flexible self-adhesive
insulating element 7 which can be wound along its longitudinal axis
to form a compact spiralled roll 14 for storage and efficient
handling and transport of the insulating element. In these and
other respects, the invention represents a practical and
commercially significant improvement over the prior art.
[0086] FIG. 7 is a schematic illustration of a wall assembly 20,
preferably a vertical wall assembly, constructed in accordance with
another embodiment of the present invention. As described in
greater detail below, the vertical wall assembly 20 incorporates a
multi-function barrier layer adapted to provide insulation and
moisture management, and facilitate cladding alignment. The wall
assembly 20 generally includes wall sheathing 21, cladding 22, and
strips of tape 23, preferably thermal break tape or foam insulation
tape, interposed between the wall sheathing 21 and cladding 22. In
some implementations, a weather resistant barrier layer 24 is
disposed on the exterior surface of the wall sheathing 21. The
cladding 22 is fastened via fasteners 25 to at least two spaced
apart studs 256 that are part of the building frame. The fasteners
25 can be nails, screws, or the like sized to extend through the
cladding 22, tape 23, sheathing 21 and into the stud 26. In certain
preferred forms, the tape 23 has a plurality of markings or
indicia, the markings being spaced relative to one another on the
operative outer surface of the tape for facilitating alignment of
the cladding 22 relative to the studs.
[0087] As shown in FIG. 7, each strip of tape 23 is sandwiched
between the cladding 22 and wall sheathing 21 in front of a stud
26, thereby creating a clearance space 27 between the cladding 22
and wall sheathing 21. The width of each strip of tape 23 may be
greater than or less than the width of the associated stud 26. In
certain embodiments, the width of each strip of tape 23 is
substantially the same as the width of the associated stud. In
certain preferred implementations, the clearance space 27 can be
maintained because the tape 23 is substantially not compressible.
In some embodiments, the clearance space 27 is very narrow, having
a width of about 5 mm to 50 mm, or a width of about 6 mm to 20 mm.
The clearance space 27 effectively functions as a rainscreen for
the vertical wall assembly 20, which allows circulation of air and
removal of condensation by being vented to the atmosphere.
Advantageously, application of the tape 23 at strategic locations
as described herein provides not only an effective lightweight
insulation barrier over studs but also an effective insulative air
barrier over bays.
[0088] FIG. 8 is a schematic illustration of a wall assembly 30,
preferably vertical wall assembly, constructed in accordance with
another embodiment of the present invention. Similar to the wall
assembly 20 shown in FIG. 7, the wall assembly 30 generally
includes wall sheathing 31, cladding 32, and strips of tape 33,
preferably thermal break tape or foam insulation tape, interposed
between the wall sheathing 31 and cladding 32. In some
implementations, the wall assembly 30 further includes an
insulation or foam insulative sheathing 38 disposed adjacent to the
sheathing 31. The foam insulative sheathing 38 further improves the
insulation R-value of the wall assembly. In one embodiment, a
weather resistant barrier layer 34 is disposed on the exterior
surface of the wall sheathing 31. In other embodiments, the weather
resistant barrier layer 34 can be applied to the exterior surface
of the foam insulative sheathing 38. As illustrated in FIG. 8, the
cladding 32 is fastened via fasteners to at least two spaced apart
studs 36 that are part of the building frame. The fasteners can be
nails, screws, or the like sized to extend through the cladding 32,
tape 33, foam insulative sheathing 38, sheathing 31 and into the
studs 36. In certain preferred forms, the tape 33 has a plurality
of markings or indicia, the markings being spaced relative to one
another on the operative outer surface of the tape for facilitating
alignment of the cladding 32 relative to the studs. The tape 33
also creates a clearance space 37 between the cladding 32 and the
foam insulative sheathing 38. The clearance space 37 can serve as
an effective rainscreen to inhibit rain or moisture from entering
the building structure.
[0089] Although the invention has been described with reference to
specific examples it will be appreciated by those skilled in the
art that the invention may be embodied in many other forms.
* * * * *