Insulation Spacer and Methods of Use Thereof

Abstract

An insulation spacer for marine vessel insulation. In one embodiment, the insulation spacer comprises a circularly-shaped top face comprising a locking means; a side wall extending from a perimeter of the circularly-shaped top face at a first angle measuring between about 90° and about 180° relative to an internal surface of the top face, thereby forming a bottom opening; a flange portion extending from a perimeter of the bottom opening at a second angle measuring equal to the first angle relative to an external surface of the side wall, whereby the flange portion is parallelly oriented to the circularly-shaped top face, wherein the side wall provides at least a ½-inch space between the circularly-shaped top face and the flange portion.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to the field of insulation, and more particularly to the field of insulation for marine vessels which must be in compliance with United States Coast Guard (USCG) regulations.

Background of the Invention

Insulation, particularly insulation within marine vessels, may be critical for providing condensation protection, a thermal barrier, and/or sound dampening capabilities, thereby preventing rusting or corrosion of the vessel as well as keeping passengers and crew safe and comfortable while onboard the vessel. Typically, marine vessel insulation may include, without limitation, an anti-sweat or anti-condensation coating, a sound dampening coating (e.g., spray-on materials), other types of known insulation (e.g., fiber insulation), or combinations thereof. To ensure optimum safety, the USCG enforces various rules and regulations, particularly in regards to the standards and practices of insulation, and among the various insulation regulations, the USCG may require a minimum air gap between coatings and other types of known insulation utilized on marine vessels. Currently, a means by which to easily, effectively, and efficiently create such an air gap between insulation layers, that is also in compliance with USCG regulations, does not exist. However, makeshift attempts often comprise the cutting of brass rods to suitable lengths and positioning said cuttings between insulation layers. This attempt may be both time consuming to construct and at least partially ineffective at maintaining the required minimum air gap.

Consequently, there is a need for an insulation spacer that may easily, efficiently, and effectively provide a means by which to create and maintain an air gap between insulation layers on a marine vessel that complies with USCG regulations.

BRIEF SUMMARY OF SOME OF THE PREFERRED EMBODIMENTS

These and other needs in the art are addressed in one embodiment by an insulation spacer for marine vessel insulation, comprising a circularly-shaped top face comprising a locking means; a side wall extending from a perimeter of the circularly-shaped top face at a first angle measuring between about 90° and about 180° relative to an internal surface of the top face, thereby forming a bottom opening; a flange portion extending from a perimeter of the bottom opening at a second angle measuring equal to the first angle relative to an external surface of the side wall, whereby the flange portion is parallelly oriented to the circularly-shaped top face, wherein the side wall provides at least a ½-inch space between the circularly-shaped top face and the flange portion.

These and other needs in the art are addressed in one embodiment by a method for insulating a marine vessel, comprising adhering one or more insulation pins to a marine vessel substrate; applying a coating onto the marine vessel substrate; installing an insulation spacer onto each of the one or more insulation pins over the coating via a locking means, wherein each insulation spacer comprises a circularly-shaped top face comprising the locking means; a side wall extending from a perimeter of the circularly-shaped top face at a first angle measuring between about 90° and about 180° relative to an internal surface of the top face, thereby forming a bottom opening; a flange portion extending from a perimeter of the bottom opening at a second angle measuring equal to the first angle relative to an external surface of the side wall, whereby the flange portion is parallelly oriented to the circularly-shaped top face, wherein the side wall provides at least a ½-inch space between the circularly-shaped top face and a flange portion; installing standard insulation onto the one or more insulation pins over each insulation spacer; installing an insulation pin cap onto each of the one or more insulation pins over the standard insulation.

The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter that form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiments disclosed may be readily utilized as a basis for modifying or designing other embodiments for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent embodiments do not depart from the spirit and scope of the invention as set forth in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a detailed description of the preferred embodiments of the invention, reference will now be made to the accompanying drawings in which:

FIG. 1 illustrates marine vessel insulation utilizing an insulation spacer according to an embodiment of the present invention;

FIGS. 2A-2B illustrate different perspective views of an insulation spacer according to one embodiment of the present invention; and

FIG. 3 illustrates a side view of an insulation spacer according to one embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention relates to an insulation spacer that may provide a means by which to create and maintain a suitable air gap or space between insulation layers of marine vessel insulation that complies with or adheres to USCG regulations. As illustrated in FIG. 1 (not to scale), insulation layers may be applied to any internal marine wall or substrate 1. In embodiments, the insulation layers may comprise, without limitation, an optional primer 3 disposed on marine substrate 1, one or more insulation pins or studs 5 disposed onto (e.g., glued, tack welded, or welded onto) optionally-primed marine substrate 1, and a coating layer 7, comprising an anti-sweat or anti-condensation coating and/or a sound dampening coating disposed on (e.g., sprayed on) optionally-primed marine substrate 1 having one or more insulation pins 5. Further, the insulation layers may comprise a standard insulation layer 9, comprising other types of known insulation, disposed over coating layer 7, as well as one or more insulation pin caps 11 disposed over standard insulation layer 9, such that one or more insulation pins 5 penetrate standard insulation layer 9 and may be subsequently capped by one or more insulation pin caps 11. In embodiments, insulation spacer 2 may be disposed between coating layer 7 and standard insulation layer 9 and held in place by one or more insulation pins 5, thereby creating and maintaining an air gap 13.

As illustrated in FIG. 2A-2B from different perspective views, insulation spacer 2 may be a uniform body component formed from any moldable material via a molding system. Alternatively, insulation spacer 2 may be a uniform body component formed from any metal material (e.g., iron, steel, or the like) via a die punch system. In such embodiments, the metal material may be galvanized to promote non-combustibility as well as to prevent possible corrosion and/or rusting. Insulation spacer 2 may comprise a top face 4, a side wall or walls 6, and a flange portion 8.

Top face 4 may be a portion of insulation spacer 2 comprising an external surface 10 and an internal surface 12. In embodiments, top face 4 may provide a footprint of any suitable shape or size for contacting external surface 12 with either coating layer 7 or standard insulation layer 9 of the marine vessel insulation, depending on direction of installation. Top face 4 may be circular, oval, elliptical, square, rectangular, or triangular in shape, or alternatively may be any other polygonal shape. In some embodiments, top face 4 may be circularly-shaped and comprise a diameter measuring between about 10 mm and about 100 mm, or alternatively between about 30 mm and 80 mm, or further alternatively about 40 mm.

In further embodiments, top face 4 may comprise a locking means 14. Locking means 14 may comprise a hole disposed through top face 4 from external surface 10 to internal surface 12. Further, the hole may be disposed at a center of top face 4 and dimensioned to receive one or more insulation pins 5, respectively. In embodiments, the hole may comprise a diameter measuring between about 1 mm and about 10 mm, or alternatively between about 2 mm and 5 mm, or further alternatively about 3 mm.

Depending on the shape of top face 4, insulation spacer 2 may comprise side wall or walls 6 extending from a perimeter of top face 4, with side wall or walls 6 comprising an external surface or surfaces 16 and an internal surface of surfaces 18, respectively. For instance, embodiments in which top face 4 may be circular, oval, elliptical, or the like, insulation spacer 2 may comprise a side wall 6 with external surface 16 and internal surface 18, whereas embodiments in which top face 4 may be square, rectangular, triangular, or any other polygonal shape, insulation spacer 2 may comprise side walls 6 with external surfaces 16 and internal surfaces 18. As further illustrated in FIG. 3, side wall or side walls 6 may extend from the perimeter of top face 4 at any suitable angle 20 relative to internal surface 12 of top face 4 and by any suitable length. Accordingly, side wall or walls 6 may form a bottom opening 22 corresponding in shape to that of top face 4. In embodiments, angle 20 may measure between about 90° and about 180°, or alternatively between about 100° and about 120°, or further alternatively about 108°. Further, the length at which side wall or walls 6 extend from the perimeter of top face 4 may be a length capable of providing at least a ½-inch distance 24 between top face 4 and bottom opening 22. This at least ½-inch distance 24 may allow insulation spacer 2 the means by which to provide suitable air gap 13 between insulation layers of marine vessel insulation, and thereby may be in compliance with USCG regulations. In further embodiments, a rounded or sharp convex edge 32, may be formed along the perimeter of top face 4 at an area in which top face 4 meets side wall or walls 6 on the external surface of insulation spacer 2.

Referring once again to FIGS. 2A-2B, insulation spacer 2 may comprise flange portion 8 extending from a perimeter of bottom opening 22, with flange portion 8 comprising a top side 26 and a bottom side 28. As further illustrated in FIG. 3, flange portion 8 may extend from the perimeter of bottom opening 22 at any suitable angle 30 relative to external surface 16 of side wall or walls 6 and by any suitable length. In embodiments, angle 30 may measure equal to that of angle 20, whereby flange portion 8 may be parallelly oriented to top face 4. Further, the length at which flange portion 8 may extend from the perimeter of bottom opening 22 may be any length capable of providing a substantial footprint of any suitable shape or size for contacting bottom side 28 with either coating layer 7 or standard insulation layer 9 of the marine vessel insulation, depending on direction of installation. In embodiments, the length at which flange portion 8 extends from the perimeter of bottom opening 22 may be between about 5 mm and about 30 mm, or alternatively between about 10 mm and about 20 mm, or further alternatively about 15 mm. In further embodiments, a rounded or sharp concave edge 34, may be formed along the perimeter of bottom opening 22 at an area in which side wall or walls 6 meet flange portion 8 on the external surface of insulation spacer 2.

Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations may be made herein without departing from the spirit and scope of the invention as defined by the appended claims.

Claims

1. An insulation spacer for marine vessel insulation, comprising:

a circularly-shaped top face comprising a locking means;

a side wall extending from a perimeter of the circularly-shaped top face at a first angle measuring between about 90° and about 180° relative to an internal surface of the top face, thereby forming a bottom opening;

a flange portion extending from a perimeter of the bottom opening at a second angle measuring equal to the first angle relative to an external surface of the side wall, whereby the flange portion is parallelly oriented to the circularly-shaped top face,

wherein the side wall provides at least a ½-inch space between the circularly-shaped top face and the flange portion.

2. The insulation spacer of claim 1, wherein the insulation spacer is galvanized metal such as iron or steel.

3. The insulation spacer of claim 1, wherein the circularly-shaped top face is dimensioned to provide a substantial footprint for contact with a substrate surface or a standard insulation surface.

4. The insulation spacer of claim 1, wherein the circularly-shaped top face has a diameter measuring between about 10 mm and about 100 mm.

5. The insulation spacer of claim 1, wherein the locking means is a hole disposed through a center of the circularly-shaped top face.

6. The insulation spacer of claim 5, wherein the hole is dimensioned to receive an insulation pin or stud.

7. The insulation spacer of claim 5, wherein the hole has a diameter measuring between about 1 mm and about 10 mm.

8. The insulation spacer of claim 1, wherein the at least ½-inch space is capable of providing an air gap between a coating and standard insulation that allows for compliance with United States Coast Guard regulations.

9. The insulation spacer of claim 1, wherein the flange portion is dimensioned to provide a substantial footprint for contact with a substrate surface or a standard insulation surface.

10. The insulation spacer of claim 1, wherein the flange portion extends from the perimeter of the bottom opening by a length between about 5 mm and about 30 mm.

11. A method for insulating a marine vessel, comprising:

(A) adhering one or more insulation pins to a marine vessel substrate;

(B) applying a coating onto the marine vessel substrate;

(C) installing an insulation spacer onto each of the one or more insulation pins over the coating via a locking means, wherein each insulation spacer comprises: a circularly-shaped top face comprising the locking means; a side wall extending from a perimeter of the circularly-shaped top face at a first angle measuring between about 90° and about 180° relative to an internal surface of the top face, thereby forming a bottom opening; a flange portion extending from a perimeter of the bottom opening at a second angle measuring equal to the first angle relative to an external surface of the side wall, whereby the flange portion is parallelly oriented to the circularly-shaped top face, wherein the side wall provides at least a ½-inch space between the circularly-shaped top face and a flange portion;

(D) installing standard insulation onto the one or more insulation pins over each insulation spacer;

(E) installing an insulation pin cap onto each of the one or more insulation pins over the standard insulation.

12. The method of claim 11, wherein each insulation spacer is galvanized metal such as iron or steel.

13. The method of claim 11, wherein the circularly-shaped top face is dimensioned to provide a substantial footprint for contact with the marine vessel substrate or the standard insulation.

14. The method of claim 11, wherein the circularly-shaped top face has a diameter measuring between about 10 mm and about 100 mm.

15. The method of claim 11, wherein the locking means is a hole disposed through a center of the circularly shaped top face.

16. The method of claim 15, wherein the hole is dimensioned to receive each of the one or more insulation pins.

17. The method of claim 15 wherein the hole has a diameter measuring between about 1 mm and about 10 mm.

18. The method of claim 11, wherein the at least ½-inch space is capable of providing an air gap between the coating and the standard insulation that allows for compliance with United States Coast Guard regulations.

19. The method of claim 11, wherein the flange portion is dimensioned to provide a substantial footprint for contact with the marine vessel substrate or the standard insulation.

20. The method of claim 11, wherein the flange portion extends from the perimeter of the bottom opening by a length between about 5 mm and about 30 mm.