U.S. patent application number 13/564214 was filed with the patent office on 2014-02-06 for fibrous insulating system with a corrugated thermal break core.
The applicant listed for this patent is Robert Cerutti. Invention is credited to Robert Cerutti.
Application Number | 20140037905 13/564214 |
Document ID | / |
Family ID | 50025758 |
Filed Date | 2014-02-06 |
United States Patent
Application |
20140037905 |
Kind Code |
A1 |
Cerutti; Robert |
February 6, 2014 |
Fibrous Insulating System with a Corrugated Thermal Break Core
Abstract
A fibrous insulation blanket manufactured to be installed
between standard, sub-standard, and super-standard framing within
those wall, ceiling, and roof cavities between framing members in
residential and commercial buildings. Said fibrous insulation
blanket includes a structure of flexible corrugated/ribbed material
serving as a structural thermal break comprised of a non-heat/cold
transmitting material, which provides additional insulating
characteristics beyond the capabilities of the fibrous insulating
material for increased protection from heat loss and cold
infiltration.
Inventors: |
Cerutti; Robert; (Milford,
PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Cerutti; Robert |
Milford |
PA |
US |
|
|
Family ID: |
50025758 |
Appl. No.: |
13/564214 |
Filed: |
August 1, 2012 |
Current U.S.
Class: |
428/167 ;
428/182 |
Current CPC
Class: |
E04B 1/7662 20130101;
E04B 2001/747 20130101; E04B 1/7612 20130101; Y10T 428/2457
20150115; Y10T 428/24694 20150115; E04B 1/78 20130101 |
Class at
Publication: |
428/167 ;
428/182 |
International
Class: |
E04B 1/78 20060101
E04B001/78; E04B 1/76 20060101 E04B001/76 |
Claims
1. This invention is a pre-sized, fibrous insulation blanket with a
structural corrugated or ribbed thermal break core. The fibrous
insulation blanket may be faced (also providing excess face
material on the interior major surface for the adhesion of this
invention via staples, adhesive material, nails, tacks, etc.) or
un-faced, treated or untreated. The corrugated thermal break may be
made from corrugated cardboard, corrugated paper, plastic,
sponge-like material, etc., and contains, maintains, and protects
pockets of air within the corrugated structure and therefore
provides increased insulative protection of the structure,
residence, building area where used from heat loss and cold
infiltration. The corrugated structural core may be faced with an
air film on both, one, or neither major face. This fibrous
insulation blanket with a structural corrugated or ribbed thermal
break core is used for insulating standard, sub-standard, and
super-standard widths and lengths of walls, ceilings, and/or roof
cavities. This thermal break core provides additional insulating
characteristics beyond the basic insulating characteristics of any
fibrous material independently. This corrugated thermal break core
is made of a material that is a poor thermal conducting amalgam
such as treated or untreated corrugated cardboard, corrugated
paper, plastic, sponge-like material, etc. and may be faced or
un-faced with an air film. This corrugated core provides increased
protection from heat loss and cold infiltration.
2. The structure of the thermal break consists of two major faces,
two minor edges, and the double surface face (two sides) of the
currugated portion between the two major surfaces. Within the
confines of the major surfaces, the minor edges, and the corrugated
structure are air spaces which are confined, constructed,
separated, and supported by the structure described above. This
plethora of separating surfaces, which provide insulating
properties on their own, combined with the air spaces, provides
additional protection beyond that which would be provided by the
same thickness of the fibrous insulation that the corrugated
structure replaces.
3. A pre-sized fibrous insulation blanket, with a structural
corrugated/ribbed thermal break core of a predetermined thickness.
This corrugated or ribbed thermal break of a predetermined
thickness is manufactured to be centralized one half the distance
between the two major faced or un-faced surfaces or any distance
proportionally placed at any other appropriate distance between the
two major surfaces of the insulating blanket and this corrugated or
ribbed thermal break core of a predetermined thickness. The core
extends from one edge or minor surface of the insulation blanket to
the opposing edge or other minor surface of the insulation blanket
and extends the entire length of the batt or roll.
4. The thermal break structure according to claim 1, wherein: the
corrugated structural core contains an amount greater or lesser
than 98% air and an amount greater or lesser than 2% actual
material. The air in the thermal break structure is located within
and between the ribs of the corrugated material and between the two
major surfaces of the corrugated structure.
5. This faced or un-faced pre-sized fibrous insulation blanket with
structural corrugated or ribbed thermal break core according to
claim 2, wherein: is superior in insulating properties and superior
in protection of the insulated area from heat loss and cold
infiltration as compared to a similar fibrous insulation blanket
containing the same overall thickness from one major surface to the
opposing major surface of fibrous insulating material but without
the corrugated thermal break core.
6. This faced or un-faced pre-sized fibrous insulation blanket with
structural corrugated or ribbed thermal break core according to
claim 1, wherein: is flexible when being installed or rolled
end-to-end with the width remaining the same and the length being
shortened into a roll. The corrugated/ribbed structure is made from
flexible, poor-temperature transmittal material, with the ribs
installed and positioned in a side-to-side, minor surface to minor
surface configuration, thus permitting the blanket to be rolled
easily into a compact package.
7. This faced or un-faced pre-sized fibrous insulation blanket with
structural corrugated or ribbed thermal break core according to
claim 1, wherein: this chemically treated or un-treated, faced or
un-faced fibrous insulation blanket with a thermal break core is
used for insulating standard, sub-standard, and super-standard
widths and lengths of walls, ceilings, or roof cavities.
8. The corrugated thermal break material according to claim 1,
wherein: is made of a material that is a poor thermal conducting
amalgam such as treated or untreated corrugated cardboard,
corrugated paper, plastic, etc. which contains, maintains, and
protects major air spacing within the structure of the corrugated
core to provide increased insulating qualities, superior to that of
just fibrous material.
9. The pre-sized fibrous insulation blanket with a structural
corrugated or ribbed thermal break core, according to claim 1,
wherein: has standard widths of 141/2'' and 221/2'' and a standard
(when naturally expanded and un-packaged) thickness of 31/2'',
51/2'', 71/2'', 91/4'' or 111/4'' or any other standard or
customized width or thickness.
10. The pre-sized fibrous insulation blanket with a structural
corrugated or ribbed thermal break core, according to claim 1,
wherein: has a standard width of 141/2'' and 221/2'' and a custom
width of any size.
11. The pre-sized fibrous insulation blanket with a structural
corrugated or ribbed thermal break core, according to claim 1,
wherein: has a standard thickness of 31/2'', 51/2'', 71/2'', 91/4''
or 111/4'' or any other standard or customized width or
thickness.
12. The pre-sized fibrous insulation blanket with a structural
corrugated or ribbed thermal break core according to claim 1,
wherein: is faced or un-faced, treated or untreated, with or
without paper, metal foil, fire retardant, adhesive, air film or
any other material or product.
13. The pre-sized fibrous insulation blanket with a structural
corrugated or ribbed thermal break core according to claim 1,
wherein: is treated or un-treated on the interior facing or
exterior facing surface with or without fire retardant
material.
14. The pre-sized fibrous insulation blanket with a structural
corrugated or ribbed thermal break core according to claim 1,
wherein: is made from treated or un-treated, faced or un-faced fire
retardant fibrous material.
15. The pre-sized fibrous insulation blanket with a structural
corrugated or ribbed thermal break core according to claim 1,
wherein: can be installed in parallel batts to fill wider than
standard wall, ceiling, roof, or other cavities.
16. The pre-sized fibrous insulation blanket with a structural
corrugated or ribbed thermal break core according to claim 1,
wherein: can be installed in several layers to provide additional
insulating values with additional thermal break insulating cores in
order to fill cavities deeper than standard cavities.
17. The pre-sized fibrous insulation blanket with a structural
corrugated or ribbed thermal break core according to claim 1,
wherein: can be installed in layers where the depth of the cavities
permits, and will provide layered corrugated thermal breaks.
18. The pre-sized fibrous insulation blanket with a structural
corrugated or ribbed thermal break core according to claim 1,
wherein: when installed in layers, will provide additional
protection from heat loss and cold infiltration beyond a single
layer with one thermal break.
19. The pre-sized fibrous insulation blanket with a structural
corrugated or ribbed thermal break core according to claim 1,
wherein: the fibrous insulation blanket may be manufactured with
more than one corrugated or ribbed thermal break core structure.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a new application.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT
DISC
[0003] Not Applicable
TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION
[0004] The present invention relates to a faced or un-faced
pre-sized fibrous insulation blanket with a structural corrugated
or ribbed thermal break core. Said structural corrugated thermal
break contains air pockets and is located between the two major
faces of the invention which is then located within the fibrous
insulation blanket. This thermal break provides additional
insulating characteristics beyond the basic insulating
characteristics of any fibrous and non-fibrous material
independently.
BACKGROUND OF THE INVENTION
[0005] A standard of the commercial and residential construction
industry is the use of fiberglass, rock wool, or spun glass fibrous
insulation, manufactured in roll or precut batt insulation packages
and is placed into walls, roofs, and ceilings.
[0006] Fibrous insulation has been a worldwide staple in the
construction industry for over 40 years. Previous to that time any
insulation was used only in the colder climates and only
occasionally in temperate climates. However, the history of this
product shows a gradual progression to where insulation is now and
for the past thirty plus years has been a requirement in most
building codes in the United States in all climates as well as
other developed countries.
[0007] Fibrous insulation, specifically, fiberglass batts and
fiberglass loose fill, are used in more homes and commercial
buildings than any other type of insulation.
[0008] Fiberglass insulation can cut the cost of heating and air
conditioning by up to 40 percent vs. a non-insulated structure. The
primary reason this insulation provides protection against heat
loss and cold infiltration is that the spun glass fibers trap air.
It is this trapped air that primarily provides this product with
its insulating properties.
[0009] Another type of insulation for buildings is loose fill
cellulose. This is a product made from small pieces of paper,
processed wood, and other organic and inorganic material. Its
insulating properties are also primarily derived from trapping air
between and within the fibrous material.
[0010] This invention is a fibrous insulation blanket containing a
thermal break core of predetermined thickness. This thermal break
core contains, maintains, and protects pockets of air within its
structure thereby providing additional and increased protection
from heat loss and cold infiltration.
[0011] This invention is a fibrous insulation blanket containing a
structural corrugated or ribbed thermal break core is pre-cut to
fit wall, ceiling, and/or roof cavities.
[0012] This corrugated thermal break core adds rigidity and
strength to the fibrous insulating blanket.
[0013] The corrugated or ribbed thermal break material would be
made from a poor thermal conducting amalgam such as treated or
untreated corrugated cardboard, paper, plastic, etc.
[0014] This fibrous insulating blanket with a corrugated or ribbed
thermal break core is manufactured in standard or custom widths in
order to be fitted into standard, sub-standard, or super-standard
structural or non-structural cavities in ceilings, walls, rafters,
dividing walls, partitions, and other such structures.
[0015] This new invention coincides with the current construction
model in application, manufacture, storage, delivery, and
marketing.
[0016] The new invention with the corrugated or ribbed thermal
break core can be rolled, stored, and applied as simply as the
current fiberglass/spun glass fibrous insulation batt and roll
product.
[0017] This new invention with the corrugated insulating core is
designed to be essentially the same thickness and same width as
current fibrous spun glass/fiberglass products thereby fitting
appropriately within the standard widths of ceiling joists, wall
studs, roof rafters, interior and exterior walls, and other framing
cavities.
[0018] Either or both major and/or minor surfaces of this product
can be faced or un-faced with or without paper, foil, cardboard,
plastic, air film, coatings, etc.
[0019] Facing on single or duel major and/or minor faces may also
be applied and the product can still be installed in the same
manner.
[0020] The fibrous insulation blanket with a corrugated or ribbed
core feature is manufactured with the ribs of the core running
widthwise from minor edge to minor edge, which assures the
flexibility of the product when rolled and packaged and during
installation.
[0021] The principal behind this innovation is to take advantage of
an already fully accepted theory that air contained within a poor
heat/cold transferring material and positioned as a thermal break,
provides greater insulating properties than the same material
without this innovation. This, even though, spun glass, cellulose,
and other fibrous materials do not conduct heat or cold well and
are adequate insulating materials on their own.
[0022] This corrugated or ribbed thermal break adds additional
resistance to the conductivity of unwanted temperature variations
from one major face and fibrous composite to the opposing major
face and fibrous composite.
[0023] The stated claims and descriptions of this invention are not
to be construed as limiting any options or modifications. It is to
be understood that the invention is not to be limited to the
enclosed embodiment, but on-the-contrary, is intended to cover any,
various, many, modifications and equivalent arrangements included
within the spirit and scope of the above claims and
descriptions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Label 1 (FIGS. 1, 2,3) shows the thermal break core
installed between an inner and outer portion of a fibrous
insulation blanket (Labels 2 and 4.)
[0025] Labels 13 and 14 (FIGS. 1, 2,3) show the protected air
pockets within the structure of the thermal break core.
[0026] Labels 17 (FIG. 2) shows the structure of the thermal break
core.
TABLE-US-00001 TABLE 1 Label Key to FIGS. 1, 2, 3 Label #
Description 1 Corrugated Thermal Break Core Structure 2 Interior
Portion of the Fibrous Insulation Blanket with a Thermal Break Core
3 Vapor Barrier (if desired) installed on the Interior Side of the
Fibrous Insulation Blanket 4 Exterior Portion of the Fibrous
Insulation Blanket with a Thermal Break Core 5 Interior Minor Face
of a Typical Wall Stud 6 End View of the Exterior Side of the
Fibrous Insulation Blanket with a Thermal Break 8 Major Face of a
Typical Wall Stud 9 Exterior Face of the Fibrous Insulation Blanket
with a Thermal Break Core 10 Major Face of a Typical Wall Stud 12
Interior Minor Face of a Typical Wall Stud 13 Air Space within the
Structure of the Thermal Break Core 14 Air Space within the
Structure of the Thermal Break Core 15 2 .times. 4 Sill Plate for
the Wall Structure 17 Corrugated Material Forming the Structure of
the Thermal Break Core 18 Interior Drywall 19 Exterior Sheathing 20
Exterior Siding
TABLE-US-00002 4,866,905 September 1989 Bihy, et al 5,765,318 June
1998 Michelsen 5,848,509 December 1998 Knapp, et al 6,141,930
November 2000 Allwein, et al 6,357,504 March 2002 Patel, et al
6,383,594 May 2002 Weinstein, et al 6,415,573 July 2002 Moulder
6,468,615 October 2002 Weinstein, et al 6,484,463 November 2002 Fay
6,551,951 April 2003 Fay, et al 6,599,850 July 2003 Heifetz
6,551,677 November 2003 Weinstein, et al 6,670,011 December 2003
Weinstein, et al 7,857,923 December 2010 Suda, et al
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