This invention relates to a new system for supporting 5 and retaining fiber insulation, for example, batt, sheet, or roll insulation on a wall, ceiling, partition or other structure surface of a building. Background Art

A number of methods are used for supporting and lOretaining fiber insulation batts, sheets, and rolls between studs or in other spaces to be insulated on walls, ceilings, partitions, and other structure surfaces of a building. Typically,, fiber insulation batts, sheets, and rolls are manufactured with paper flanges which are tacked 5or stapled to wooden studs of the wall or beams of a ceiling or floor. A disadvantage of this conventional approach is that the fiber insulation tends to sag over time* and part with the paper flanges. Further, this method is not suitable for steel buildings, metal wall studs, and 0metal roofs and floors.

. According to another approach, metal nail-like prongs or bars are secured at right angles- to the wall or other surface of the void to be insulated. .A disadvantage of the nail-like prongs or bars is that they create a hazardous 5environment at the workplace location creating a risk for workers. Furthermore,, the nail-like spikes are incorporated in a frame which is limited for use with studs of a particular on-center spacing. The approach is not well adapted, for the variable spacing of metal studs or for 0masonry walls.

Miller U.S. Patent No. 1,915,611 describes a "keeper" plate with sharp prongs issuing or extending outwardly from each side of the plane of the plate. The keeper functions as a supporting sheet with an insulation panel or block 5embedded on the prongs on each side to form a prefabricated insulating slab. The Sevink U.S. Patent No. 4,389,190 describes a metal supporting plate with sharp punched protrusions for embedding into mineral and synthetic insulating material blocks and panels. for furnaces.

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Neither the keeper nor the supporting plate is applicable for supporting fiber insulation batts, rolls or sheets on a wall, ceiling, or partition or other structure surfaces of a building and they function only as the internal or adjacent binding support for rigid fibrous material bodies embedded on either side. Furthermore, the issuing or extending prongs or protrusions are not foldable by installation workers. The prongs of the type contemplated by Miller and Sevink would have to be preformed by a achine punch during manufacture. Nor are the prongs or protrusions in. the configuration of elongate arrows with at least one barb on the free end to facilitate securing and retaining fiber insulation batts or sheets impaled on the prongs. German Patent 2730525 to Schuhmann describes a fixture or bracket for holding mineral fiber or foamed insulation panels on steel structures _^ Each of the fixtures is an approximately square bracket formed of doubly bent sheetmetal in a "U" or "Z" configuration. The single piece brackets are intended for supporting rigid insulation panels. The bracket is formed with a tongue which is bent vertically outward and upward from the plane of the bracket. The tongue passes through a slotted retaining piece and is fαlded over for holding an insulation panel against the wall or other steel structure. The German Patent does not provide or disclose elongate insulation support members maintained in the plane of the fixture or bracket and constructed so that they may be grasped and folded outward by an installation worker bending the prongs or insulation members at the stem end. Nor are the "tongues" of the German Patent reference formed in an arrow-like configuration for impaling soft fiber insulation such as fiberglass insulation with barbs for supporting and retaining the insulation. Schuhmann's individual fixtures or brackets are intended for an entirely different type of insulation, namely the rigid mineral fiber or foamed insulation panels and are primarily intended for edge support of such panels.

Similarly, the Lamm U.S. Patent No. 2,580,231 describes brackets, for suspending ceiling panels, lath, pipe and conduit from ceilings and is not adapted for supporting retaining fiber insulation batts, sheets and rolls against walls and other structure surfaces.

Objects of the Invention

It is therefore an object of the present invention to provide' a new system and method for installing, supporting and retaining fiber insulation, either thermal or sound insulation, for example, in the form of batt, sheet or roll insulation; and to provide a system applicable for use on a wall, ceiling, partition or other structure surface which is easily installed on any material building surface such as metal, masonry or wood and which prevents sagging or parting of the insulation.

Another object of the invention is to provide a system for supporting and retaining insulation which may be installed initially in a form which does not present risks to workers and which does not create, a hazardous environment. Thereafter, the form of the support system may be readily converted by installation workers at the site for supporting and retaining insulation as it is installed.

A further object of the invention is to provide a system for supporting and retaining insulation which may be readily manufactured in quantity and stored and shipped in compact form for rapid installation and preparation at the building site. The system is sufficiently flexible for use with any building- system or material, or any on-center spacing of studs, ^' rafters or beams..

Disclosure of the Invention

In order to accomplish these results , the present invention provides a system of flange base plates constructed and arranged with a flat bearing face portion for bearing against a structure surface such as a wall, ceiling or partition. The ^* flange base plates are formed with means for securing the bearing face to the structure surface. The flange base plates are formed with one or more elongate insulation support members having a free end

and a stem end merging with the flange base plate. The insulation support members are constructed to be foldable at the stem end by installation workers to extend at an angle from the flange base plate for supporting fiber insulation. Each elongate support member is formed with a declining taper at the free end for impaling and supporting insulation on the support member and with at least one barb at the' free end for retaining the impaled insulation.

A feature and advantage of the invention is that the elongate insulation support members are initially formed generally in the same plane with the flange base plate for installation and distribution of the flange base plates over a structure surface with the elongate insulation support members lying in substantially the same plane of the structure surface. This safety feature affords a safe environment for workers at the site, and installation workers may subsequently fold the elongate insulation support members at an angle projecting from the flange base plates for support of insulation when it is installed. Retaining washers may also be used comprised of a flat retaining surface with at least one slot for receiving an elongate support member and engaging the barb at an edge of the slot. The retaining washer therefore bears against the thermal insulation or sound control materials impaled on the elongate support member.

The flange base plates may be secured to a structure surface in a number of ways. According to one embodiment of the invention, the flange base plate is provided with an adhesive layer on the flat bearing surface for adhering to a structure surface of any of a variety of materials.

Alternatively, or additionally, the flange base plates are formed with holes for receiving nails, screws, or other securing members. The invention is thus adapted for any building system or for any on-center spacing of structural building materials.

The invention contemplates a variety of other configurations for the system. In prior pending U.S. Serial No. 360,220 an elongate strip is formed with a row of arrow-like elongate support members having the elongate

axes directed parallel with the elongate axis of the strip.

The present invention provides that the strip is rolled into a roll or reel of multiple contiguous turns for compact storage and shipping. The insulation support members are maintained flush with the rolled strip or reel during storage and shipping and during installation and are thereafter folded at an angle to the structure surface for supporting insulation. According to other configurations, the present invention provides a furring strip suitable for application ofits flat bearing surfaces to, for example, masonry walls. Similarly, the invention may be in the configuration of purlin runners for supporting ceiling insulation.

In yet another embodiment, the invention provides a system of metal studs formed with the elongate support members as-an integral part of the stud to be folded outwardly at an angle for supporting insulation in the space or void between studs.

Other objects, features and advantages of the present invention will become apparent in the -following specification and accompanying drawings.

Brief Description of the Drawings

Figure 1 is perspective view of a system for supporting and retaining fiber insulation in a strip configuration according to prior U.S. Serial No. 360,220; while Figure 1A is a plan view of the insulation supporting and retaining strip in a compact roll or reel for storage and shipping according to the present invention.

Figure 2 is a perspective view of the insulation supporting and retaining strip of prior U.S. Serial No.

360,220 in place on a wall in preparation for installing insulation, either thermal insulation or sound control materials.

Figure 3 is a fragmentary perspective view of a furring strip configuration of the insulation supporting and retaining system according to the present invention.

Figure 4 is a plan view of an individual flange base plate embodiment of the present invention with the insulation support member flush with the plate for

placement on a structure surface; while Figure 4A shows the insulation support member folded at the stem for impaling insulation.

Figure 4B is a partial side cross section of the individual flange base plate of the type illustrated in Figure 4A with the addition of an adhesive layer.

Figure 5 is a diagrammatic view of an individual support of ^" the type illustrated in Figure 4A showing the use of a slotted retaining washer.

Figure 6 is a plan view of an alternate retaining washer.

Figure 7 is a plan view of an individual flange base plate insulation support having a support member with a single barb..

Figure 8 is a fragmentary perspective view of a metal stud insulation supporting and retaining system while Figure 8A is a cross sectional view through the stud.

Figure 8B is a fragmentary perspective view of another metal stud insulation supporting and retaining system.

Figure 9 is a diagrammatic view of an elongate insulation support member according to the invention having a double fold or bend for retaining insulation. Description of Preferred Example Embodiments and Best Mode of the Invention

A strip configuration insulation supporting and retaining system as described in prior pending U.S. Patent Application Serial No. 360,220 is illustrated in Figures 1 and 2. The strip configuration support system 10 is composed ^* of a flat strip 12 with- elongate ^" support members 14 i the configuration of an arrow punched or cut in the strip 12. Each elongate support member 14 therefore has a free ^" end 15 in the configuration of an arrowhead with double barbs and a stem end 16 merging with the strip 12. Prior to installation on a wall or other structure. surface and after installation but before insulation is applied, the elongate support members or arrows 14 remain flush with the strip 12 as indicated by the unfolded arrow 18.

The undersurface of the strip 12 forms a bearing face applied to a wall, ceiling,, partition or other structure

surface 20 as illustrated in Figure 2. In this application the strips 10 are applied to the wall 20 between studs 22 before the studs are set in place. At this time the elongate support members or arrows 14 remain in the plane of the strip generally flush with the wall so as not to subject workers to unnecessary hazards. Prior to application of the insulation 24 which may be, for example, in the'form of sheet, batt, or roll insulation, the arrows or members 14 are folded outward from the stem end 16 at an angle from a strip in the wall for impaling the insulation

24 as it is applied.

For support of the insulation 24 without sagging the strips 10 are typically applied at intervals, for example, of four feet providing rows of support members 14 at intervals of four feet one above the other. The top strip

1Q may be, for example, positioned ^* in the order of four inches (10 cm) to ten inches (25 cm) below the top of the studs 22. The strips 10 are also applied spaced on either side of seams where one insulation sheet, roll or batt ends and another begins. The support members or arrows 14 have a minimum length of from three inches (7.5- cm) to five inches (12.5 cm) and longer depending upon the width of the insulation and the length of the insulation support members is selected to match the thickness of the fiber insulation batts, sheets or rolls to be supported. The support members or arrows 14 are typically spaced, for example, eight inches (20 cm) apart along the strip or a greater density may be used to provide at least two arrows extending outwardly from the strip between each _. pair of studs.

The strip 12 may be securely applied to a wall or other structure surface in a variety of ways, for example, the under surface or bearing surface of the strip 12 may be provided with an adhesive layer exposed by peeling off a protective paper cover for application to any of a variety of material surfaces or is applied with a separate bonding agent. Alternatively, the strip is- provided with spaced holes for application of nails, screws, rivets or other securing members.

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According to the present invention, the gauge of the strip material may range, for example, from 16 to 26 gauge and preferably closer to 26 gauge metal so that the strip

10 may be readily formed, stored and shipped in a compact roll or reel as illustrated in Figure 1A. As there shown, the arrows or support members 14 remain flush with the strip 12 in the roll or reel.

A 'furring strip embodiment of the present invention for the insulation support system is illustrated in Figure 3 applicable for use, for example, on masonry surfaces. In this embodiment the furring strip 30 is provided with an elevated rib or furrow 32 with folded bearing faces 33 for application to the support surface of masonry or other material. The bearing faces 33 may be secured by nails, screws, rivets, and adhesive layer or other means. The elevated rib or plate portion 32 of the furring strip is formed with the punched or cut out elongate support members 34 in this example in the same arrow configuration having a free end 35 in the configuration of an arrowhead with a pair of barbs 35a and 35b. During shipping and initial installation _^ the elongate support member 34 rests flush with the rib or plate 32 as shown at 38 and upon application of the insulation, is first folded or bent at the stem 36 to project outward at an angle from the furring strip for impaling insulation as shown in Figure 3.

The insulation support system of the present invention may also be provided by a plurality of individual flange base plates as illustrated in Figures 4 thru 7. As shown in Figure 4, the individual elongate support member 44 is formed by cutting or punching from appropriate gauge metal sheet along with an individual flange base plate 42. The length of the elongate support member 44 is selected to match the thickness of the insulation to be supported. The elongate support member 44 is formed with a free end 45 in the arrowhead configuration with a pair of barbs 45a and 45b and a stem end 46 which merges with the base plate 42.. The individual base plate and support members 40 may then be distributed over a structure surface defining a void to be filled with insulation. The flange base plates 42 may

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be secured by, for example, nails, screws, rivets, etc. through holes 47 and the support member or arrow 44 remains flat, that is substantially coplanar with the structure surface and flush with the base plate 42 until the insulation is ^" to be applied. At the time of applying the insulation, the arrow members 44 may be lifted and folded or bent at the stem end 46 by installation workers as shown in Figure 4A to project outwardly at an angle for impaling and receiving the insulation. An alternative arrangement for securing the individual base plates and support members to a wall or other structure surface is illustrated in Figure 4B where the base plate and support member 50 comprises a flange base plate 52 formed with an adhesive layer 53 on the bearing face for adhesive securing to the surface of the wall, ceiling, or other structure surface. The flange base plate may also be applied and secured to a structure surface using a separate bonding agent. As heretofore described, the flange base plate 52 is integrally formed with the elongate support member 54 having a free end 55 in the configuration of an arrowhead and a stem end 56 from which it is folded or bent outward at an angle from the plate 52 by the installation workers.

As shown in Figure 5, the individual base plate and support member 40 of the type illustrated in Figures 4 and

4A may be provided with a retaining washer or disk 48 having a slot 49 for sliding over the support member 44.

The edge 49a of slot 49 engages a barb 45a of the free end

45 of the arrow member 44 for retaining and holding in place insulation impaled on. the arrow member. The washer

48 of Figure 5 is provided with a slot 49 having an open end for sliding over the side of the arrow member. An alternative washer 58 is shown in Figure 6 with an internal slot 59 of sufficient width to fit over the arrowhead at the free end 45 of the support member 44 engaging a barb at either edge of the slot.

Yet another individual flange base plate and support member 60 is shown in Figure 7 in which the support member

64 having a free end 65 is more in the configuration of a

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spear or hook with a single barb 65a. The stem end 66 as heretofore described merges with the flange base plate 62 and the base plate 62 is formed with holes 67 for securing to a structure surface. It is also apparent that a combination of securing methods may be used for the individual base plate support member 60, for example, a combination of an adhesive layer on the bearing surface and nails, 'screws, rivets or other securing members. In other configurations the stem 44 of the support member of Figure 5 or the stem 64 of the support member of Figure 7 may be formed with a first "arrowhead" or "spearhead" at the tip and a second one half way down the stem for greater fiber insulation holding and retaining capability.

The present invention also provides a metal stud insulation support and retaining system as illustrated in Figures 8 and 8A. In this system configuration the metal studs 80 themselves comprise the plates in which the support members 84 are stamped or cut. Each metal stud 80 includes a major cross sectional dimension spanned by a plate 82 and a minor cross sectional dimension span by bearing surfaces 83 which bear against the walls, partitions, or other structure surfaces. The metal studs 82 may be formed of relatively thin gauge sheet metal, for example, in the range of 16 to 24 gauge and are formed with a row of a plurality of elongate support members stamped or cut in the plate 82 of metal stud 80. As heretofore described, each elongate support member 84 is provided with a free end 85 which may be in an arrowhead configuration and a stem 86 which merges with the plate 82 of the major cross sectional dimension of stud 80. The arrow members 84 may remain flush with the plates 82 following installation of the studs and when insulation is to be applied in the voids between the studs the arrow members 84 are then folded or bended by installation workers to extend into the space between the studs and impale the insulation from the sides. In this respect the arrowheads 84 may be designed to be longer than arrow members projecting at right angles from the wall 20 itself.

Another metal stud configuration is shown in Figure 8B. The metal stud 90 is provided with a side plate 92 having a wider edge or major dimension 9.3 in which are formed the elongate insulation support members or arrows 94 5 with a free end 95 in an arrowhead configuration and a stem end 96 which merges with the wider edge 93. Wider edge 93 faces the insulation while narrower edge or minor dimension 97 adds rigidity to the stud 90 as does ridge 93a formed in the wider edge 93.

10 While the invention has been described with reference to particular example embodiments, it is apparent that the system for supporting and retaining insulation may assume a variety of configurations. For example, the furring strip 30 of Figure 3 may be adapted to function as purlin runners

15 for hanging insulation on vertical walls or other structure surfaces. Similarly,, in any of the embodiments, the free end 75 of a support member 74 may be folded over at a location 77 below the barbs of the arrowhead in addition to the fold at the stem end 76 ^' as shown in Figure 9. The

20 second fold-or double fold at location.77 just below the head at the free end 75 may be used to secure insulation in place or to secure a retaining washer of the type illustrated in Figures 5 and 6. In the various embodiments of the invention, the tapered free end of the insulation

25 support member may be provided with a rounded or blunted tip rather than a sharp tip as a further work-safety measure. The insulation support member can also.be formed with a first "arrowhead" at the tip and a second arrowhead half way down the stem for greater insulation holding

30. capability.