CONICELLA NICK (CA)
BANG WON KYU (KR)
BANG SONG HYUK (KR)
US6805076B2 | 2004-10-19 | |||
US5321861A | 1994-06-21 | |||
US2845637A | 1958-08-05 |
CLAIMS: 1. An insulated blanket kit comprising: a shell comprising a first layer and a second layer including perimeter stitching providing a finished edge to a perimeter of the shell, the first and second layers being joined together about at least a portion of the perimeter of the shell by said perimeter stitching so as to define an enveloped space within the shell having a length spanning in a longitudinal direction between a portion of the perimeter stitching at a first end and a portion of the perimeter stitching at a second end of the shell and having a width spanning in a lateral direction between respective portions of the perimeter stitching at two opposing sides of the shell; and a liner sheet formed of a heat insulating material; the liner sheet being flexible, having a length which is substantially equal to or less than the length of the enveloped space, and having a width which is substantially equal to or less than the width of the enveloped space, so as to be arranged to be fully received within the enveloped space between the perimeter stitching at the opposing sides of the shell and between the perimeter stitching at the first and second ends of the shell. 2. The blanket kit according to claim 1 wherein the first layer of the shell further comprises: a first panel spanning laterally between the two opposing sides of the shell and spanning Iongitudinally between a first end of the first panel at the first end of the shell and a second end at an intermediate location between the first and second ends of the shell; and a second panel spanning laterally between the two opposing sides of the shell and spanning longitudinally between a first end of the second panel at an intermediate location between the first and second ends of the shell and a second end of the second panel at the second end of the shell; wherein the liner sheet is arranged to be inserted into the enveloped space of the shell through an opening in the shell defined between the second end of the first panel and the first end of the second panel of the first layer of the shell. 3. The insulated blanket kit according to Claim 2 wherein the first end of the second panel is at an intermediate location between the first and second ends of the first panel such that an inner end portion of the first panel adjacent the second end thereof overlaps an inner end portion of the second panel adjacent the first end thereof. 4. The insulated blanket kit according to either one of Claims 2 or 3 wherein the opening in the first layer of the shell is generally centred in the longitudinal direction between the first and second ends of the shell. 5. The insulated blanket kit according to any one of Claims 2 through 3 wherein the opening in the first layer of the shell is offset in the longitudinal direction towards one end of the shell. 6. The insulated blanket kit according to any one of Claims 2 through 5 wherein an inner end portion of the first panel adjacent the second end thereof overlaps an inner end portion of the second panel adjacent the first end thereof and wherein the insulated blanket kit further comprises intermediate stitching penetrated through the inner end portions of both the first panel and the second panel of the first layer, the liner sheet, and the second layer. 7. The insulated blanket kit according to any one of Claims 1 through 5 further comprising a plurality of fasteners arranged to be penetrated through the layers of the shell and the liner sheet therebetween. 8. The insulated blanket kit according to Claim 7 wherein at least some of the fasteners are penetrated through the first and second layers of the shell and the liner sheet therebetween at spaced apart positions about a full perimeter of the shell. 9. The insulated blanket kit according to either one of Claims 7 or 8 wherein the fasteners are penetrated through the layers of the shell and the liner sheet therebetween in a grid pattern at laterally and longitudinally spaced positions relative to one another. 10. The insulated blanket kit according to any one of Claims 7 through 9 wherein each fastener comprises i) a first member including a shaft, a head at a first end of the shaft having an enlarged dimension relative to the shaft and a penetrating tip at a second end of the shaft, and ii) a second member comprising a head having an enlarged dimension relative to the shaft and which is arranged for snap fit connection to the penetrating tip. 11. The insulated blanket kit according to any one of Claims 1 through 10 wherein the liner sheet comprises a single, unitary piece of flexible foam material which spans the full width and the full length of the enveloped space. 12. The insulated blanket kit according to any one of Claims 1 through 11 further comprising an edging member of reinforcing material overlapping a perimeter of the shell, the edging member being joined to the first and second layers by the perimeter stitching. 13. The insulated blanket kit according to any one of Claims 1 through 12 wherein a perimeter edge of the liner sheet is recessed inwardly relative to the perimeter stitching such that the perimeter edge of the liner sheet is freely movable within the envelope space relative to the first and second layers of the shell. 14. A method of assembling the insulated blanket kit according to any one of Claims 1 through 13 comprising: stitching the first and second layers of the shell together with the perimeter stitching to form the enveloped space; and inserting the liner sheet into the enveloped space through the opening in the shell subsequent to any perimeter stitching of the shell. 15. The method according to Claim 14 wherein: the first layer of the shell further comprises: (i) a first panel spanning laterally between the two opposing sides of the shell and spanning longitudinally between a first end of the first panel at the first end of the shell and a second end at an intermediate location between the first and second ends of the shell; and (ii) a second panel spanning laterally between the two opposing sides of the shell and spanning longitudinally between a first end of the second panel at an intermediate location between the first and second ends of the shell and a second end of the second panel at the second end of the shell; and the method further comprises: (i) inserting the liner sheet into the enveloped space of the shell through an opening in the shell defined between the second end of the first panel and the first end of the second panel of the first layer of the shell; and (ii) penetrating intermediate stitching through inner end portions of both the first panel and the second panel of the first layer, the liner sheet, and the second layer to close the opening in the shell. |
FIELD OF THE INVENTION
The present invention relates to an insulated construction blanket comprising a shell and an insulating foam liner received in the shell, of the type which is commonly used for insulating spaces under construction, for example in the curing concrete and the like.
BACKGROUND
During various construction projects in colder climates, for example in the construction of buildings or various infrastructure projects including roads, bridges and the like, it is common to make use of insulated construction blanket to create a construction space that insulated from the cold temperatures, for example for curing concrete and the like. A typical insulated construction blanket comprises a layer of heat insulating material surrounded by a shell. The layer of heat insulating material and both layers of the shell are typically joined by stitching penetrated through all three layers to fix the liner relative to the shell at the perimeter of the liner and shell only.
Due to the high labour costs associated with stitching, it is typical to manufacture the entire blanket including the heat insulating material stitched therein in countries with lower labour costs followed by shipping of the assembled construction blanket to colder climates where the blanket is used. Due to the low density of the typical foam materials used for the insulating layer, the resulting blankets typically occupy a considerable shipping space despite their low weight and density. Despite this inefficiency in shipping costs, is still generally considered cheaper to assemble the entire blanket including the foam material used as an insulating layer therein to avoid the high labour costs associated with stitching the blanket together. Various prior art designs include variations to the use of material used as the insulating layer, however, the overall cost of the blanket remains relatively high in view of the inefficient shipping costs associated therewith.
SUMMARY OF THE INVENTION
According to one aspect of the present invention there is provided an insulated blanket kit comprising:
a shell comprising a first layer and a second layer including perimeter stitching providing a finished edge to a perimeter of the shell, the first and second layers being joined together about at least a portion of the perimeter of the shell by said perimeter stitching so as to define an enveloped space within the shell having a length spanning in a longitudinal direction between a portion of the perimeter stitching at a first end and a portion of the perimeter stitching at a second end of the shell and having a width spanning in a lateral direction between respective portions of the perimeter stitching at two opposing sides of the shell; and
a liner sheet formed of a heat insulating material;
the liner sheet being flexible, having a length which is substantially equal to or less than the length of the enveloped space, and having a width which is substantially equal to or less than the width of the enveloped space, so as to be arranged to be fully received within the enveloped space between the perimeter stitching at the opposing sides of the shell and between the perimeter stitching at the first and second ends of the shell.
By providing a liner with dimensions which are less than or equal to the dimensions of the enveloped space in the shell defined by the perimeter stitching, the liner sheet can be inserted into the enveloped space of the shell subsequent to the manufacturing assembly of the shell. Accordingly, all of the expensive labour relating to stitching the layers of the shell together can remain in a country where labour costs are lower, while still minimizing shipping costs because the blankets can be shipped much more efficiently without the low density insulating material used for the liner sheet being shipped therein. Foam sheets for forming the liner can instead be manufactured in the local market of the consumer to be inserted into the already stitched shell subsequent to shipping. The additional use of penetrating fasteners which can be penetrated through all of the layers of the shell and the liner sheet allow a final assembly step to take place using low skilled labour with minimal or no costly tooling being required. The overall cost to deliver a finished, assembled, insulated construction blanket to a consumer can thus be reduced compared to prior art configurations of and methods of constructing insulated construction blankets.
According to another important independent aspect of the present invention, the first layer of the shell may further comprise:
a first panel spanning laterally between the two opposing sides of the shell and spanning longitudinally between a first end of the first panel at the first end of the shell and a second end at an intermediate location between the first and second ends of the shell; and
a second panel spanning laterally between the two opposing sides of the shell and spanning longitudinally between a first end of the second panel at an intermediate location between the first and second ends of the shell and a second end of the second panel at the second end of the shell;
wherein the liner sheet is arranged to be inserted into the enveloped space of the shell through an opening in the shell defined between the second end of the first panel and the first end of the second panel of the first layer of the shell.
The first end of the second panel may be located at an intermediate location between the first and second ends of the first panel such that an inner end portion of the first panel adjacent the second end thereof overlaps an inner end portion of the second panel adjacent the first end thereof.
The opening in the first layer of the shell may be generally centred in the longitudinal direction between the first and second ends of the shell, or alternatively may be offset in the longitudinal direction towards one end of the shell.
When an inner end portion of the first panel adjacent the second end thereof overlaps an inner end portion of the second panel adjacent the first end thereof, the insulated blanket kit may further comprise intermediate stitching penetrated through the inner end portions of both the first panel and the second panel of the first layer, the liner sheet, and the second layer.
The insulated blanket kit preferably further includes a plurality of fasteners arranged to be penetrated through the layers of the shell and the liner sheet therebetween. Some of the fasteners may be penetrated through the first and second layers of the shell and the liner sheet therebetween at spaced apart positions about a full perimeter of the shell. Other fasteners may be penetrated through the layers of the shell and the liner sheet therebetween in a grid pattern at laterally and longitudinally spaced positions relative to one another.
Each fastener preferably includes i) a first member including a shaft, a head at a first end of the shaft having an enlarged dimension relative to the shaft and a penetrating tip at a second end of the shaft, and ii) a second member comprising a head having an enlarged dimension relative to the shaft and which is arranged for snap fit connection to the penetrating tip.
The liner sheet may comprise a single, unitary piece of flexible foam material which spans the full width and the full length of the enveloped space. The insulated blanket kit may further include an edging member of reinforcing material overlapping a perimeter of the shell in which the edging member is joined to the first and second layers by the perimeter stitching.
Preferably a perimeter edge of the liner sheet is recessed inwardly relative to the perimeter stitching such that the perimeter edge of the liner sheet is freely movable within the envelope space relative to the first and second layers of the shell.
According to another important independent aspect of the present invention there is provided a method of assembling the insulated blanket kit including: (i) stitching the first and second layers of the shell together with the perimeter stitching to form the enveloped space; and (ii) inserting the liner sheet into the enveloped space through the opening in the shell subsequent to any perimeter stitching of the shell.
When the first layer of the shell further comprises (i) a first panel spanning laterally between the two opposing sides of the shell and spanning longitudinally between a first end of the first panel at the first end of the shell and a second end at an intermediate location between the first and second ends of the shell; and (ii) a second panel spanning laterally between the two opposing sides of the shell and spanning longitudinally between a first end of the second panel at an intermediate location between the first and second ends of the shell and a second end of the second panel at the second end of the shell, the method may further include: (i) inserting the liner sheet into the enveloped space of the shell through an opening in the shell defined between the second end of the first panel and the first end of the second panel of the first layer of the shell; and (ii) penetrating intermediate stitching through inner end portions of both the first panel and the second panel of the first layer, the liner sheet, and the second layer to close the opening in the shell.
BRIEF DESCRIPTION OF THE DRAWINGS
One embodiment of the invention will now be described in conjunction with the accompanying drawings in which:
Figure 1 is a top plan view of the assembled insulated blanket according to the present invention;
Figure 2 is a sectional view of the assembled insulated blanket along the line 2-2 in Figure 1 ; and
Figure 3 is a sectional view of the components of the insulated blanket shown separately from one another generally along the line 2-2 in Figure 1.
In the drawings like characters of reference indicate corresponding parts in the different figures.
DETAILED DESCRIPTION
Referring to the accompanying figures there is illustrated an insulated construction blanket generally indicated by reference numeral 10. The blanket 10 is particularly suited for use in colder climates to provide an insulating layer, for example forming an enclosure about a construction space, or as a blanketing layer over a floor or wall where materials require curing, for example concrete and masonry applications. The blanket serves to insulate the enclosed space or the supporting surface being covered from the surrounding climate to maintain temperatures above freezing for example.
The blanket is typically initially manufactured as a kit of parts that includes a manufactured hollow shell and a liner sheet 50 arranged to be subsequently assembled with the hollow shell at a different location from the initial manufacturing location. The hollow shell of the kit of parts is formed of a first layer 12 and a second layer 14 which span opposing first and second sides of the shell. More particularly the first and second layers each span a full length of the shell in the longitudinal direction thereof between a first end 16 and a second end 18, as well as spanning a full width of the shell in the lateral direction thereof between two opposing sides 20.
The second layer 14 in the illustrated embodiment comprises a single panel of flexible sheet material which spans the full area of the shell between the opposing ends and opposing sides thereof. The second layer may be formed of a sheet of polyethylene skin material, or other material having similar performance characteristics.
The first layer 12 is formed of a first panel 22 and a second panel 24 which collectively span the full area of the shell at the first side thereof between the opposing ends and opposing sides thereof. The panels of the first layer may also be formed of a sheet of polyethylene skin material, or other material having similar performance characteristics.
Each of the first panel 22 and the second panel 24 individually spans the full width of the shell in the lateral direction between the two opposing sides thereof. In the longitudinal direction, however, the first and second panels are supported substantially longitudinally in series with one another.
More particularly the first panel spans between a first end 26 thereof at the first end of the shell and an opposing second end 28 at a first intermediate location in the longitudinal direction between opposing ends of the shell. The second panel spans between a first end 30 at a second intermediate location in the longitudinal direction between opposing ends of the shell and a second end 32 at the second end of the shell.
The first end 30 of the second panel is situated between the first and second ends of the first panel in the longitudinal direction such that an inner end portion 34 adjacent the second end of the first panel overlaps an inner end portion 36 of the second panel adjacent the first end thereof. The first and second panels are initially constructed so as to define a slotted opening between the inner end portions 34 and 36 thereof which extends the full width of the shell in the lateral direction between the opposing sides 20 of the shell.
The first and second layers of the hollow shell are provided with finished edges and are joined to one another by perimeter stitching 40 which is penetrated through both layers about the full perimeter of the shell in the illustrated embodiment. The perimeter of the second layer corresponds to the perimeter of the single panel forming the second layer. The perimeter of the first layer corresponds to the first end of the first panel, the second end of the second panel, and both side edges of both the first and second panels,
In the illustrated embodiment, an edging member 42 is provided about the full perimeter of the shell to reinforce the edge of the shell. The edging member includes a first flange portion 44 and a second flange portion 46 which are joined at an outer fold therebetween such that the edging member is generally U shaped about the perimeter edge of the shell and such that the first flange portion overlaps a corresponding portion of the first layer 2 at the first side of the shell and the second flange portion 46 overlaps a corresponding portion of the second layer 14 at the second side of the shell. The perimeter stitching 40 is located in one or more rows of stitching, in which each row of stitching is penetrated through both first and second layers of the edging member, and both the first and second layers of the shell received therebetween. At the seam where the inner end portions of the first and second panels of the first layer overlap one another, the stitching is further penetrated through both the first and second panels of the first layer.
In further embodiments, the perimeter edges of the shell may instead be finished by folding over the sheeted material of the first and second layers of the shell followed by use of the perimeter stitching 40 to retain the edges in a folded over condition. Accordingly, the perimeter stitching 40 assists in forming or defining the finished perimeter of the shell, whether or not an edging member is provided.
Grommets 48 are provided at spaced positions along each of the side edges and end edges of the shell so as to be spaced along the edging member 42 (or folded over edges of the shell) about the full perimeter of the shell.
The assembled shell includes a hollow interior between the first and second layers thereof forming an enveloped space suitable for receiving the heat insulating liner sheet 50 therein as described in further detail below. The overall length of the enveloped space is defined by the longitudinal distance between the edge stitching 40 at the opposing first and second ends 16 and 18 of the shell. The overall width of the enveloped space is defined by the lateral distance between the edge stitching 40 at opposing sides 20 of the shell.
The liner sheet 50 comprises a single, unitary, uniform, flexible sheet of material which is sized to fit within the enveloped space of the shell. In alternative arrangements, the liner sheet 50 may comprise a plurality of separate sheets which are joined to one another or joined to respective portions of the shell so as to form a generally continuous heat insulating layer which extends the full width and length of the enveloped space. Typically, the liner sheet 50 has a length which is equal to or slightly less than the length of the enveloped space and a width which is equal to or slightly iess than the width of the enveloped space. In this manner, a perimeter edge of the liner sheet is recessed inwardly relative to the perimeter stitching such that the perimeter edge of the liner sheet is freely movable and floating within the envelope space relative to the first and second layers of the shell. The liner sheet 50 is sufficiently flexible to allow ready insertion of the liner sheet through the slotted opening between the inner end portions of the first and second panels of the first layer.
In the illustrated embodiment, the slotted opening between the inner end portions of the first and second panels of the first layer of the shell is oriented to span in the lateral direction at a central location in the longitudinal direction. In alternative embodiments, the slotted opening may be offset in the longitudinal direction towards either one of the first or second ends of the shell, or yet further, the slotted opening may be oriented to extend longitudinally, or at various non-perpendicular orientations relative to the ends or side edges of the shell.
In yet further embodiments, the slotted opening may be provided at one end of the shell such that both the first and second layers comprise a single panel of material. Each panel would be finished at the respective perimeter edges thereof by folding over, by use of an edging member, or both as described above; however, one end of both of the first and second layers would remain separated from one another in this instance for separate attachment subsequent to insertion of the liner.
In another embodiment, both the first layer and the second layer are formed as a single panel joined to one another about the full perimeter thereof; however, a slotted opening is cut into the first layer and the edges of the opening are finished with suitable edging and the like to provide access for inserting the liner after the stitching of the first and second layers together. An additional panel of material may also be used solely for overlapping and closing the slotted opening after insertion of the liner if desired.
In a preferred embodiment, the slotted opening is oriented to extend in the longitudinal direction of greatest overall length of the shelf at a central location in the lateral direction to provide greatest accessibility to the interior of the shell for ease of insertion of the liner.
The kit of parts for being assembled into a finished, insulated blanket further Includes a plurality of fasteners 52 which are penetrated through both first and second layers of the hollow shell and the liner sheet therebetween in the finished, assembled configuration of the blanket. Each fastener 52 includes a first member 54 and an opposing second member 62 joined to one another from opposing sides of the assembled blanket.
The first member 54 of each fastener has a shaft portion 56 extending between a first head 58 at one end and a penetrating tip 60 at the opposing end which forms a retaining shoulder thereon. The penetrating tip is suitably arranged to allow a user to push the shaft by penetration through both layers of the shell and the liner therebetween.
The second member 62 of each fastener is in the form of a washer defining a second head having an aperture therein arranged to receive the shaft 56 of the first member therethrough subsequent to the penetrating tip 60 being snap fit through the aperture.
In use, the user positions the second member 62 against one of the first or second layers of the shell and then penetrates the first member 54 through all layers of the blanket from the opposing first or second side until the penetrating tip is inserted through all layers, and then subsequently through the aperture in the second member 62 to provide a snap fit retention of the penetrating tip into the second member. The first and second heads of the fastener 52 are enlarged in dimension relative to the diameter of the shaft 56 such that the layers of the blanket are effectively clamped between the opposing first and second heads at respective ones of the first and second sides of the shell in the assembled configuration of the fasteners.
The fasteners 52 are penetrated through all of the corresponding layers of the blanket at respective mounting locations which are arranged in an array or grid pattern at laterally and longitudinally spaced positions relative to one another. More particularly, some of the fasteners 52 are provided at spaced apart positions along each of the ends and sides of the shell at a location spaced inward from the perimeter edge so as to be aligned with the enveloped space receiving the liner sheet therein so that the perimeter fasteners are similarly penetrated through both layers of the hollow shell and the liner sheet received therebetween in proximity to the perimeter edge of the liner sheet. The perimeter edge of the liner sheet typically remains unsecured within the enveloped space relative to the stitching between the inner and outer layers of the shell.
In alternative embodiments, different types of fasteners may be used, such as fasteners inserted from only one side of the blanket in the manner of a staple, or an expanding type of fastener such as a rivet for example.
In some embodiments, a plurality of the fasteners 52 are also arranged in one row at laterally spaced positions through the inner end portions 34 and 36 of both first and second panels along the full length of the slotted opening at the first side of the shell to close the slotted opening in the assembled configuration.
In the preferred embodiment shown in the Figures, the opening between the first and second panels of the first layer of the shell is instead closed by one or more rows of intermediate stitching 64. The intermediate stitching is penetrated through all of the layers including the inner end portions 34 and 36 of both first and second panels of the first layer, the second layer and the liner sheet, along the full length of the slotted opening between opposing side edges of the shell.
In practice, the first and second layers of the shell are assembled together with perimeter stitching in the configuration described above such that the slotted opening remains open at the completion of the manufacture of the shell. The manufactured shell can then be transported relatively economically to the location of the end consumer where locally available foam sheet material can be inserted to fully span the enveloped space of the shell subsequent to any perimeter stitching of the shell. The fasteners 52 can then be penetrated through both layers of the shell and the liner sheet therebetween to retain positioning of the liner sheet relative to the first and second layers of the shell by simply pushing the penetrating tips of the fasteners through the layers of the blanket without any special tooling being required. Additional intermediate stitching is also penetrated through both first and second layers of the shell for joining the layers of the shell subsequent to insertion of the liner sheet so that the liner sheet is also captured by the intermediate stitching.
Since various modifications can be made in my invention as herein above described, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense.
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