Building Insulation and Siding Connector

Abstract

A connector strip is mechanically attached to the planar surface defined by wooden or metallic walls. In a first embodiment the connector strip has an elongate I-beam configuration with a proximal end having transverse arms that define a flattened base that is attachable to the wall. A central rib member extends from the proximal end and is transverse to the plane of the transverse arms. The distal end of the connector strip is also defined by arms that are transverse to the central rib and which define an insulation board receiving slot between the arms on the proximal and distal ends. The arms at the distal end-the outer end of the connector strip when it is attached to a wall, serve as a surface onto which exterior materials such as siding and sheetrock may be anchored with nails or screws.

Description

TECHNICAL FIELD

The present invention relates to an extruded member used for attaching insulation board and siding or sheetrock to the walls of new construction or retrofitted on existing buildings, and more specifically, to an extruded member that has a base plate on a proximal end that may be attached to an existing wall, and retaining arms on the distal end that serve to attach to the insulation board and also provide a base to which siding or wall paneling may be nailed.

BACKGROUND

Most buildings have exterior walls that are either wood or metal. For example, most wood-framed buildings have plywood or oriented strand board (OSB) sheathing that is attached to stud framing and which is typically covered with a barrier wrap material, and then with siding. Metal-sided buildings typically have their exterior walls sheathed in some form of metallic paneling. While these materials have many useful characteristics that lead to their frequent use, it is known that walls of many structures, even those structures that have added insulation, do not have high thermal resistance or insulating properties and can therefore benefit from added insulation for improving energy efficiency. But attaching additional layers of building materials such as insulating panels and siding to wood or metal-sheathed walls is often difficult and time consuming. As such, use of exterior insulating layers is rarely done on buildings that have either wood or metal walls.

The present invention provides an apparatus and method for overcoming the problems associated with attaching insulating layers and exterior (and interior) covering layers to wood and metal walls.

The invention is defined by an extruded connector strip that is mechanically attached to the planar surface defined by wooden or metallic walls. Generally described, the connector strip has an elongate I-beam configuration with a proximal end having T-shaped arms that define a flattened platform or base plate that is attachable to a wall with the connector strip in a desired orientation relative to the wall. A central rib member extends from the proximal end and is transverse to the plane of the T-shaped arms. The distal end of the connector strip is also defined by T-shaped, transverse retaining arms that are transverse to the central rib and which retain insulation board against the wall. The retaining arms at the distal end-the outer end of the connector strip when it is attached to a wall, serve as a surface onto which exterior materials such as barrier wrapping, siding and sheetrock may be anchored with nails or screws. The connector strip is thus a single piece member that requires no drilling and which allows mechanical attachment of insulation and siding to either the exterior or interior wall of wood and metal-sided buildings.

The connector strip may be used above grade level and below grade for basement or earth sheltered building construction. In most installations the connector strip will be oriented vertically on the wall. However, in some instances the strip may be oriented horizontally, or in some other desired relationship with the wall.

The connector strip according to the present invention may be used with the Masonry Insulation Siding Connector that is described in my copending U.S. patent application Ser. No. 13/209,915, filed Aug. 17, 2011. More specifically, the invention described and claimed herein may be used in combination with the masonry siding connector described in the just-referenced application where a wall structure transitions from wood to concrete block or concrete wall. As noted, the present invention may also be used with all-wood or all-metal buildings, and to retrofit existing constructions to add additional insulation and to add siding.

A building that utilizes the connector strip according to the present invention has improved thermal efficiency and improved insulation value, with associated reductions in heat loss, improved comfort, and economic savings through reduced heating and cooling expenses.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood and its numerous objects and advantages will be apparent by reference to the following detailed description of the invention when taken in conjunction with the following drawings.

FIG. 1 is a perspective view of a short length of an extruded connector strip according to a first illustrated embodiment of the present invention.

FIG. 2 is an end elevational view of the extruded connector strip of FIG. 1.

FIG. 3 is a cross sectional view showing the connector strip of the present invention assembled with a typical wood wall, and attaching insulating board and siding to the strip.

FIG. 4A is a sectional view of a typical 2×4 inch wall assembly constructed using the connector strip according to the present invention and showing an outside corner design, showing the connector strip with typical 3 inch insulation board.

FIG. 4B is a view similar to FIG. 4A except showing use of the connector strip according to the present invention used in connection with a typical 2×6 inch wall assembly, showing the connector strip with typical 2 inch insulation board.

DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENTS

A first illustrated embodiment of a connector strip 10 according to the present invention is shown in isolation in FIG. 1. Connector strip 10 is preferably fabricated as a monolithic, one-piece unit from a plastic material that has the desired properties of strength and rigidity. There are numerous polymeric materials that will suffice for use in fabricating the connector strip, and since the strip is preferably formed of a polymeric material it may be extruded into long sections for delivery to a job site in a convenient form such as a bundle. On the job site the strip is cut to desired lengths. While polymeric compounds are the preferred materials for making the connector strip according to the present invention, the connector strip may also be fabricated from metals such as aluminum.

Relative directional terms are used at times to describe parts of the invention and relative positions of the parts. As a naming convention, the ground plane is considered to be the surface of the ground and, for purposes herein, is considered to be a horizontal ground plane although of course in use the ground plane has slope and irregularities. Other relative directional terms correspond to this convention: “upper” refers to the direction above and away from the ground plane; “lower” is generally in the opposite direction, “inner” or “inwardly” is the direction from the exterior of the structure toward the interior, and so on.

With reference to FIGS. 1 and 2, it will be understood that the connector strip 10 as used at a job site is an elongate member that is cut to length; however, in FIG. 1 only a short section of the connector strip is illustrated in order to describe the structure.

The connector strip is generally described as an elongate I-beam member. The proximal end of connector strip 10 is identified with reference number 14 and the distal end of the strip is identified with reference number 16. As detailed below, the proximal end 14 is the end that is mechanically attached to a wall. The connector strip 10 is defined by a central rib member 18 that begins at proximal end 14 and terminates at the distal end 16 at a T-shaped, transverse distal nailing member 20 that extends away from the central rib 18 on both sides thereof and which defines a portion of a slot 22 that is adapted for receiving an insulation board and which also defines a seat for nails that attach siding or other exterior materials to the connector strip. The exterior surface 21 of distal nailing member 20 defines a planar surface that extends transverse to the plane defined by central rib 18 and the distal nailing member extends over the entire length of the connector strip.

The proximal end 14 of the connector strip 10 is also defined by a T-shaped, transverse proximal nailing member 24 that extends away from the central rib 18 on both sides thereof and which, in combination with distal nailing member 20, defines slot 22 between the proximal and distal ends. As noted, slot 22 is adapted for receiving the insulation board and it retains the insulation board in place. Proximal nailing member 24 further defines a base plate through which nails that attach the connector strip 10 to the wall are driven, and as with distal nailing member 20, in the preferred embodiment, proximal nailing member 24 extends over the entire length of the connector strip 10. The base surface 26 of proximal nailing member 24 is a planar surface that is transverse to the plane defined by central rib 18.

In FIGS. 1 and 2 it may be seen that the width of proximal nailing member 24 (dimension A) is slightly less than the width of distal nailing member 20 (dimension B). However, it will be appreciated that the relative width of these two structural elements is not critical and they could both be the same width, or dimension A could be less than dimension B.

With specific reference to FIG. 2, the distance between the interior surface of nailing member 20—that is, surface 32, and the facing interior surface of nailing member 24—surface 34—is defined and identified as dimension C. As detailed below, the space between surfaces 30 and 34 defines slot 22, which again is a recess into which insulation board rests in the assembled wall section. The size of dimension C may be varied to accommodate insulation board of different thicknesses, and standard sizes for dimension C are nominally 1½, 2, 3 or 4 inches.

Turning now to FIG. 3, the method of installation of connector strip 10 with wall 36 and insulation board 48 and siding 50 will be detailed. As previously noted, the wall 36 that is being insulated may be any type of wood, metal or even plastic wall and it may be interior or exterior. As shown in FIG. 3, the wall 36 overlies supporting structures such as the stud 38. An elongate piece of connector strip 10 is cut to an appropriate length and the proximal end 14 of the strip 10 is placed against the wall as shown in FIG. 3 with the planar surface 26 flush against the wall and preferably so that the connector strip overlies the supporting structure such as stud 38. In most instances, the connector strip will be oriented vertically on the wall, but as noted, vertical orientation is not required. With the connector strip placed as desired on wall 36, a nail 40 is then driven through proximal nailing member 24 on one side or the other of the central rib 18, as shown. In lieu of a nail 40, an appropriate fastener for the particular circumstances may be used (such as screws or rivets). Preferably, the length of nail 40 is sufficient for the nail to penetrate the stud 38. Plural nails 40 are then driven into the connector strip in a like fashion along its length, until the connector strip is securely attached to the wall. Appropriate construction adhesives may be used in place of or in addition to nails to attach the connector strip to the wall.

With the connector strip 10 attached to wall 38 as just described, the connector strip is firmly and securely attached to the wall 36.

With one connector strip 10 attached to wall 36, a section of insulation board 48 is inserted into the slot 22 defined between central rib 18, proximal nailing member 14 and distal nailing member 20. The insulation board 48 is of a size appropriate for dimension A, which is the width of the slot 22 into which the board 48 fits as shown in FIG. 3. Typical insulation board 48 is 15⅞ inches or 23⅞ inches in width and either 1½, 2 or 3 inches thick. A second connector strip 10 is attached to the opposite edge of the insulation board 48 and the second connector strip 10 is attached to the wall 36 as described above so that the insulation board is firmly retained against the wall 36 between adjacent connector strips 10. The process is repeated over the part of the wall 36 that is to be insulated.

Once the insulation board 48 is applied over the entire wall, exterior siding 50 (or interior covering such as sheetrock 50 if connector strip 10 is being used with an interior wall) may be installed. The siding 50 is nailed with appropriate fasteners such as nails 42 (preferably ring shank nails) or screws driven through the siding 50 and the distal nailing member 20. The connection between the nails 42 and the plastic distal nailing member 20 is very secure and prevents unintended removal or loosening of the siding over time.

FIGS. 4 and 5 are details illustrating use of the several connector strips 10 according to the present invention to attach several pieces of insulation board 48 in a wall, illustrating a typical outside corner detail (the wall sections shown in FIGS. 4A and 4B both include a window wrap detail). FIG. 4A shows a standard 2×4 inch framed wall with an insulation board 48b having a first thickness (e.g., 3 inches), and in FIG. 4B the wall is a standard 2×6 inch framing but the insulation board 48c is less thick than the board 48b (e.g., 2 inches). In both figures the wall 36 to which insulation board 48 is applied is defined by wooden sheathing such as plywood or OSB that is attached to standard framing such as studs 38. With reference to FIG. 4A, a connector strip 10 is attached to the wall 36 as noted above. The insulation board 48a is then inserted into the slot 22 (FIG. 3) and the board is pressed against wall 36. In FIG. 4A the lateral edge 52 of insulation board 48 is aligned flush against the ganged corner studs 54 and 56 so that the insulation board 48a is snugly retained between the connector strip 10 along one lateral edge, and the ganged corner studs 54 and 56 along the opposite lateral edge 52. In this circumstance there is no need for a connector strip 10 along the lateral edge 52. The same is seen with insulation board 48b, which is inserted into the slot 22 on the opposite side of connector strip 10 from insulation board 48a. In that case, the lateral edge 58 of insulation board 48b is pressed against and aligned with ganged studs 60 and 62 of the window wrap. Siding 50 is applied as detailed above and desired corner details are installed.

The only difference between FIGS. 4A and 4B is in the thickness of the insulation board, 48a in FIGS. 4A and 48c in FIG. 4B. As noted above, insulation board is available in a number of different thicknesses. FIG. 4B is thus an illustration of the use of a connector strip 10 in which the slot 22 is sized to adapt to an insulation board having a different thickness.

Those of ordinary skill in the art will recognize that certain modifications may be made to the connector strip described herein without departing from the scope of the claimed invention. As one example, as noted above, in the preferred embodiment the proximal nailing member 24 extends over the entire length of the connector strip 10. However, and with reference to FIG. 5 and connector strip 100, in some instances it may be desirable to replace the proximal nailing member 24 with intermittent tabs 66 that extend transversely from the central rib member 18 along the length of the connector strip—the nails 40 are driven through the intermittent tabs 66a and 66b to attach the connector strip 10 to the wall 36. The nailing tabs 66a and 66b may extend from alternating sides of the central rib 18.

As another example, it is possible to modify a connector strip for specific installation situations to remove the portion of the nailing members on one side of the central rib, effectively changing the overall shape of the connector strip from an elongate I-beam configuration to an elongate C-beam configuration. Thus, connector strip 102 illustrated in FIG. 6 illustrates such a C-beam configuration has modified nailing members on both the proximal and distal ends. This type of C-beam connector strip is useful in an installation such as shown in FIG. 4A where the lateral edge 52 of insulation board 48 is aligned flush against the ganged corner studs 54 and 56 so that the insulation board 48a is snugly retained between the connector strip 10 along one lateral edge, and the ganged corner studs 54 and 56 along the opposite lateral edge 52, thereby eliminating the need for an C-beam configuration connector strip 10 along the lateral edge 52. With connector strip 102 the portion of the nailing members on one side of the central rib 18 have been removed so that there is a proximal nailing member 68 at proximal end 14 and a distal nailing member 70 at distal end 16. This embodiment provides additional connective strength for attaching the insulation board to the wall at the appropriate installation locations.

It will be appreciated that the nailing members shown in FIG. 5 that are defined by plural tabs such as 66a and 66b may be applied to the C-shaped connector strip shown in FIG. 6, as well.

Finally, it will be evident that the nailing member 20 need not be a solid piece along its entire length. Instead, it may include voids, alternating or otherwise, in order to save on the amount of material used to make the connector strip.

While the present invention has been described in terms of preferred and illustrated embodiments, it will be appreciated by those of ordinary skill that the spirit and scope of the invention is not limited to those embodiments, but extend to the various modifications and equivalents as defined in the appended claims.

Claims

1. A connector for attaching insulation and siding to a wall, comprising:

a central rib section;

a first nailing member extending transverse to the central rib section at a proximal end thereof; and

a second nailing member extending transverse to the central rib section at a proximal end thereof.

2. The connector according to claim 1 in which the first and second nailing member extends from the central rib section on both sides thereof.

3. The connector according to claim 2 wherein the first and second nailing members are spaced apart to define a space for receiving insulation between the first and second nailing members.

4. The connector according to claim 1 in which the first and second nailing member extends from the central rib section on only one side thereof.

5. The connector according to claim 2 in which the first nailing member extends over the entire length of the connector.

6. The connector according to claim 1 in which the first nailing member is defined by plural tabs that extend from said central rib section.

7. The connector according to claim 6 in which said tabs alternate on both sides of said central rib section.

8. The connector according to claim 4 in which the first nailing member is defined by plural tabs that extend from said central rib section.

9. The connector of claim 1 in combination with a wall in which the connector is attached to the wall with fasteners driven through the first nailing member and into the wall to thereby attach the connector to the wall, and including an insulation board retained between the first nailing member and the second mailing member, and further including siding attached to the connector with a fastener driven through the siding and into the second nailing member.

10. A connector for attaching insulation and siding to a wall, comprising:

a central section having first and second sides and proximal and distal ends;

a retaining means at the proximal end of the central section for attaching said connector to said wall;

a nailing member at a distal end of the elongate central section and said nailing member defined by arms extending transversely from said central section at the distal end thereof and on the first and second sides thereof; and

a slot defined between the retaining means and the nailing member.

11. The connector according to claim 10 wherein the retaining means further comprises a nailing member defined by arms extending transversely from said central section at the distal end thereof and on the first and second sides thereof.

12. The connector according to claim 11 wherein the slot is configured for receiving a lateral edge of an insulation board.

13. The connector according to claim 10 wherein the nailing member is defined by tabs extending transversely from said central section.

14. The connector of claim 10 in a wall layout comprising:

a wall;

wherein the connector is attached to the wall with fasteners driven through the retaining means to thereby attach the connector to the wall; and

an insulation board retained against the wall in the slot between the retaining means and the nailing member.

15. The connector of claim 14 in a wall layout further comprising siding attached to the nailing member with fasteners driven through the siding and into the nailing member.

16. A method of attaching insulation board to a wall, comprising the steps of:

a) attaching a connector to a wall by driving fasteners through a first nailing member on a proximal end of said connector, wherein said connector is defined by a member having a central rib section, a first transverse nailing member extending transverse to the central rib section and a second transverse nailing member extending from the central rib section at a distal end thereof to define an insulation board receiving slot between the first and second transverse nailing members; and

b) attaching insulation to the connector to retain the insulation board against the wall by inserting a lateral edge of the insulation board into the receiving slot of the connector.

17. The method of claim 16 including the step of attaching siding by applying siding over the insulation board and driving fasteners through the siding and the second transverse nailing member.

18. The method of claim 17 including the step of attaching a second connector to the wall, the second connector having an insulation board receiving slot, and inserting a second lateral edge of the insulation board in the insulation board receiving slot of the second connector.

19. The method of claim 18 including the step of attaching siding by applying siding over the insulation board and the first and second connectors and driving fasteners through the siding and second transverse nailing members of both the first and second connectors.