GB2628912A - Loft storage and insulation solution - Google Patents

Abstract

A method for installing an insulating layer into a roof space uses interlocking panels to form an insulating layer within various roof spaces. Means to position and securely fasten the panels without jeopardising the layer’ insulating properties are included. Panels for use in the method comprise a planar slab of insulation material having edges with interlocking formations. The panels can be coupled to adjacent panels. Guidelines may be provided on the top surface of the panel and the base of the panel may have a recess for a joist. Tubes may extend through the panels and be connected when adjacent panels are interlocked. The panels may be secured by fasteners inserted at indicia provided on the top surface of the panel. The guidelines may be used to determine where to cut apertures in the panels to accommodate features projecting from the floor of the roof space. Wires may be run in the tubes through the panels.

Description

Loft storage and insulation solution

Background

The present invention relates to a roofing structure that may be implemented in various buildings. More specifically, the claimed invention provides an insulated roofing structure that can be implemented in various roof types such as loft structures or flat roofs.

The most common method for insulating roof spaces requires the use of fiber blankets or similar materials, which are then placed over the existing roof structure, such as being placed over or between joists. These materials are often provided in large rolls that need to be laid over the surface of the insulated space. However, such rolls of material can be hard to transport and may be difficult to pass through the usually small access hatches, or doors, to a roof space due to their large size. Further, these fibrous materials may be difficult to position as the materials may fall apart, especially when held in-situ on the slope between roof rafters. Furthermore, these fibrous materials can be hazardous to install as they will often need cutting down to size, which may result in the release of fibers that can be hazardous when inhaled, thereby requiring the user to use suitable safety equipment when installing such insulation. Additionally, these blankets are often simply laid over or between the joist of the insulated roof, without any suitable means of fastening them into place and often leaving gaps between the blankets and the adjacent blanket or joist. Such gaps may create cold bridges wherein heat can escape through the insulating layer. Further such gaps may allow moisture to enter through the insulating lay and build in the space below increasing the risk of damp and mold forming in the roof space and potentially damaging the roof joists or rafters. Lastly, these fiber blankets may also form a fire risk if the materials used are not suitably flame retardant as the loose fibers may ignite, and could cause the wooden roof structures to catch fire.

An alternative to such fiber blankets includes using wooden inlays, wherein a wooden floor is installed over the joists to create a space that can be filled with insulating material to form an insulating layer. However, such an inlay requires precision tools and a lot of work to install compared to the blankets as the floor needs to be fitted to the insulated space. Further, the increased weight of the inlay may reduce the amount of weight that can be stored within these spaces. Lastly, this insulation can be costly as in addition to costs of the initial installation of the wooden panels of the inlay, there will eventually be a need to replace the inlay as they will degrade over time. Meaning a skilled workman would need to fit the replacement panels increasing the cost and work needed compared to the alternatives. This need to be replaced is also true for the fiber blankets described above as over time the fibers may degrade or move apart under the force of the objects stored in the roof space, allowing cold bridges to form across the insulating layer.

Therefore, there is a need to provide an alternative roof insulation that is easy to install and preferably has a small size and is made of a lightweight material to allow easier transportation and installation. This new installation would also preferably be able to carry a large weight without breaking and would be flame retardant. Thereby providing an effective insulating layer that can be easily installed and replaced without the need for a skilled workman or specialized tools. Preferably this alternative insulation would also be configured to not degrade over time thereby providing improved insulation compared to the current methods.

The claimed invention goes a step further by providing this insulation as part of the roof structure thereby making it easier for users to install as such insulation can be implemented during the construction of the building. It is noted that such structures would need to follow additional building regulations when compared to the insulation methods described above.

For example, such structures would need to provide ventilation and may also need to provide waterproofing to the roof structure. Therefore, the claimed invention provides a roof structure with in-built insulation that meets each of these building requirements and may be adapted to a variety of roofing structure types.

Summary

The present invention provides an improved method of installing roof structure insulation that can be adapted to a wide range of different roof structures while requiring minimal tools and labour.

This method is achievable in part by the type of insulation being used. In this case, the insulation is in the form of a series of interlocking insulation panels, wherein the sides of each panel comprise one or more protrusions and/or one or more cavities configured to receive the protrusion from an adjacent panel. With these panels, the user can form a layer of insulation by interlocking the adjacent panels of a plurality of panels. This insulating layer can be formed within the desired roof structure to quickly form insulation over a desired area.

When using the above panels, the user can stack the panels in transit making the insulation easier to transport compared to the rolls of insulation usually used. Additionally, the panels can be sized to easily access openings in the roof structure, such as a loft hatch. It is noted that the preferred embodiment of the above-mentioned panels would be 1200 x 400 x 125mm in dimensions, this size ensures that the panels can access a range of different roof structures easily.

As noted above the claimed method of installing insulation would comprise transporting a plurality of interlocking panels into the desired roof structure. Once in the location, the user may place the first panel onto the base of the roof structure. Once the first panel is in place the user may place a second panel adjacent to the first. The user can then interlock the first and second panels by inserting the protrusion of one panel into the cavity of the other panel. It should be noted that in some embodiments the panel will include protrusions and cavities evenly spaced on all sides, in some cases, the protrusions may be shapes such that the spaces between each protrusion form a suitable cavity. This way each side of a given panel can be interlocked with any side of any other panel, allowing the user to interlock each of the panels regardless of their alignment.

In some cases, around the edges of the structure, there may not be sufficient room for an entire panel, especially as some roof structures would require space for ventilation around the edges of the structure. When this occurs, the user can cut the panels down to the desired size, while still being able to be interlocked with the edge panels. In some cases, the top surface of the panel may include guidelines to assist the user in cutting the panel to the required size. For example, the surface of the panel may comprise a plurality of evenly space guidelines that the user can use to get a rough estimate for the size of the panel pieces they are cutting.

It is also noted that in some roof structures, there may be supporting structures that extend upwards from the base of the roof structure. In these cases, the user may need to cut an aperture or slot into the panel to house such features within the panel. The above guidelines may also be used to assist the user in measuring the size and position of the aperture or slot cut into the panel, thereby reducing the risk of the slot being cut into the panel incorrectly.

Further, the base of most roof structures includes joists or similar horizontal support structures. In these cases, the panels may include recesses on the bottom face of the panel, wherein the size and location of the recesses are configured to receive the joist. It is noted that for most roof structures such joists have a known size and are spaced a known distance apart, these standards can be used to ensure that the recesses are positioned to align with the joist, and are a suitable size to receive the joist. It is noted that the panel may include a pattern of recesses, with overlapping recesses in perpendicular directions, such that the panel can still receive the joists regardless of the panel alignment. Additionally, the panel may include a recess along the edges of the panel such that the connection between the panels forms a recess that can receive a joist.

It is noted that by recessing the joists into the panel as described above, the panels may use the joists for additional support, as the panel will be able to dissipate the force of any weight placed on the top panel into the recessed joints. This allows the panels to support more weight and reduces the risk of a panel breaking. Additionally, these recesses help ensure that the layer of panels has a level surface across the entire roof structure, as without these recesses the parts of the panel that rests on the joist may be raised relative to the other panels.

Once the panels have been placed over the roof structure as described above, the user may choose to fasten one or more of the panels in place to help avoid the risk of the panels sliding, especially when someone is walking over the panels. In particular, the user may pass a fastener through the panel and into the joist, or other support structure under the panel to secure the panel in place. Wth such fasteners inserted the user can help ensure that the panels do not slide once placed and prevent the panels from becoming decoupled. In such cases, the top surface of the panel may include indicia to highlight the location where such fasteners can be inserted to secure the panel.

It is noted that many types of fasteners can be used for securing the panel, such as nails, screws, or nuts. However, there is a problem, some of these fasteners are made from a thermally conductive material, which may result in the fastener forming a heat bridge through the panel layer, similarly, the hole around the fastener may allow small drafts through the panel again forming a heat bridge through the panel layer. Therefore, it is preferable to use a fastener that provides some insulation or is made from an insulating material to prevent the formation of such heat bridges. To this end, the most preferable form for the fastener comprises self-drilling insulation screws, such screws can be inserted through the panel and the joist without the need to drill a hole thereby reducing the risk of such a drilled hole forming a heat bridge through the panel. Further, these fasteners will be made from an insulating material, or at least be coated in an insulating coating, thereby preventing the fastener from conducting heat through the panel. In addition to these screws, the preferred fasteners would use insulating washers, these are typically wide washers made from an insulating material. The purpose of these washers is to cover the aperture around the screw and acts as an insulating barrier to prevent air from traversing through the space between the screw and the panel material. This helps prevent the formation of heat bridges through the panel, thereby providing improved insulation while still allowing the panels to be fastened into place.

In some cases, the panels may include one or more insulated tubes that extend laterally through each panel. These tubes can be used to pass wires, or pipes, through the panels.

This means that the wires can be hidden within the panel layer such that they do not form a trip hazard to anyone who is walking over the panel. It is noted that these tubes are formed with open ends in the sides of the panel, and are positioned such that the tubes in adjacent panels will be aligned to form a continuous tube through the panel layer. However, it is noted that these tubes would be open at the ends of the layer and therefore risk forming a heat bridge through the panels. To prevent this the panels may include insulating caps that can be placed over the ends of the tubes to help prevent airflow through the panels to prevent heat bridges from forming through the panels.

It is noted that the user may wish to seal the tubes if they are not in use. In these cases, the user may insert a sealant into the tube such as an insulating expanding foam, to both seal and insulate the tubes. The panel may be supplied with a flexible external tube which may be coupled to the open end of a tube for inserting the insulating material into the tube. When this material is inserted and set/hardened the insulating material may help bind the panels together as the insulating material bridges the space between the panels and may help glue the panels together, further reducing the risk of the panels separating.

However, in some cases, it may not be possible to reach the side of the panel layer to insert the external tube into the panel openings. In such cases, the panels may include one or more vertical tubes, which extend from the lateral tubes in the panel to the upper surface of the panel. The user can access these pipes can be used to insert the insulating material as described above, even when the sides of the panel are inaccessible. These vertical pipes may be sealed with an insulating cap when not in use to prevent heat bridges from forming through the panel. Alternatively, these vertical pipes may be embedded within the panel such that the top of the pipe is covered by a flap or lip made from the panel material, allowing the user to controllably open the pipe by folding back the flap. Either way the user will be capable of inserting the sealing foam without the need to access the sides of the panels.

Once the panels are secured in this manner the user will be able to repeat the process for other panels until a complete layer is formed over the desired roof space. It is noted that in some cases the user may need to leave space around the edges of the insulating layer so that air can circulate into the roof space. Therefore, it may be desirable to use air-porous insulation, such as fiberglass insulation around the edges of the insulating panels so as to allow air to travel through the edges of the insulation allowing ventilation of the roof space. In some cases, the user may also lay a layer of such material beneath the panel layer to help further improve the insulation in the roof space by utilizing different forms of insulation.

In some cases, the insulating block may include a reflective layer coupled to one or both planar sides of the panel. This reflective layer allows the panels to reflect heat into the areas being insulated. This reduces the risk of heat penetrating the panel layer and may improve the layer's ability to trap heat within the roof space and/or the building below the layer.

It is also noted that the insulating layer as described above when layered over the floor of the roof space can provide a platform allowing personnel to walk over the roof space, with the panel layer acting as a reinforced floor for the personnel to walk over. This would also allow the users to store items within the roof space by resting them on the panel layer.

Regardless of the specific panel design chosen, a user may wish to implement such panels during a building's construction rather than after the structure is built, they may wish to install the panels inside the roof structure. In these cases, the user may choose to lay a layer of the claimed panels inside one or more surfaces of the roof structure. For example, the user may place a layer of the above-mentioned panel over the base of a roof structure, below the joist of the roof, or with the slope walls of the roof structure. In these cases, the user will not need to position the panel over joists or other supporting structures as the panels will be underneath such structures. However, it should be noted that the panels may need to be positioned with the joist recess facing upwards, such that the joist above the panel rests within the recess. This helps ensure that the layer of panels remains flat and is not bent or otherwise deformed by the roof structures above it. This also allows the user to secure the panels in place without the need for external fasteners as the roof structure will hold the panel layer in place.

The benefit of placing the panels within the roof structure, as previously mentioned, is that the panels will be held in place as part of the structure without the risk of sliding or the need for external fasteners. Another benefit is that the user may now place flooring over the panel layer without the risk of breaking the panels. This may be preferable if the user wishes to use the attic space in the building for storage or as another bedroom. In this structure, the flooring would rest of the supporting structure, such as joists, instead of the panels. Meaning there is no risk of the flooring damaging the panels.

It is also noted that the installation of such panels can provide a base which may be used to storage solution, for storing items, or at least more items within the roof space. More specifically, the panels as described above can form a layer over the joists within the roof space with sufficient strength for multiple people to stand upon the panels, with no risk of the panels bending or breaking. As such the user is able to store more items within the roof space, as the user can dissipate the weight of such objects over the panel layer, thereby allowing the user to store more objects when compared to placing them on the joists alone. It is also noted that the panel layer would provide a larger surface area to place objects on when compared to the joists alone. It is noted that the claimed solution also provides an improvement compared to placing a flooring, such as a wood flooring, as the panels provide insulation to the roof space, which would not be achieved with a wood flooring, or similar flooring.

Detailed Description

The present invention is represented in the following figures, please note that in the figures like features are represented with matching reference numerals.

Figure 1 -depicts the top side of an example of an insulating panel used to form the insulating layer Figure 2 -depicts the base side of an example of an insulating panel used to form the insulating layer Figure 3 -depicts an example insulating panel comprising lateral and vertical tubes Figure 4 -depicts a cross-section of a roof structure that includes the panelled insulating layer Figure 5 -The figures comprise the following features: -insulating panel -interlocking protrusion -interlocking cavity -measurement lines/marking indicia 50 -joist recesses -joist shoulder -small joist protrusion 71 -large joist protrusion -elongate longitudinal internal tube (horizontal tube) 82 -elongate lateral tube (horizontal tube) 84 -end of elongate lateral tube 86 -aperture perpendicular to and intersecting lateral tube to enable foam injection for sealing the lateral tube (vertical tube) -roof tiles -Air porous insulating material 110 -Joist The present invention provides a method of installing insulating panels into a roof space such as a loft or flat roof. The invention also comprises a plurality of panels that are used to form this insulating layer.

Figures 1 and 2 depict an example of the panels 10 that can be used to produce an insulating layer in a roof space. The depicted panel comprises a rigid insulating material such as expanded polystyrene such that each panel is made of an insulating material that can be cut and shaped into the desired design for the insulating panel. This material may also include additives such as graphene to improve the panel's ability to absorb or reflect inferred radiation. In some cases, the panels may include a reflecting metallic layer that is positioned over the top, base, or both sides of the panel again to increase the panels' ability to reflect inferred radiation. Both of these features allow the panels to better redirect heat back into the building or roof space into which the panels are installed.

Figure 1 depicts the top side of the insulating panel as used in the claimed invention. The top of the panel 10 comprises a plurality of guidelines 40 wherein the guidelines are positioned regularly across the length and width of the panel 10. These lines 40 can be used as a rough guide to help the user measure the size of the panel, this may be used when placing the panel at the edges of the roof space, or in a corner where there is not sufficient space for a whole panel. Additionally, in some roof spaces, there may be supporting structures that rise out of the base of the roof structure that may obstruct the panels. In such cases, the user may use these guidelines to measure where in the panes to cut an aperture or slot to house the support structure. It is noted that such slots should have extra spacing around the structure, typically between a half-inch to an inch, this extra space allows air to circulate and be ventilated around the structure to reduce the risk of mold forming on the structure, and provides better ventilation to the roof space.

The figure also shows an example of the interlocking features located along the sides of the panel. In general, the interlocking features are configured to be coupled to a corresponding interlocking feature on the side of an adjacent panel. By using such features all of the panels in the roof space can be coupled to form a single solid layer over the entire roof space. In the depicted example the interlocking features comprise a plurality of protrusions 20 and a corresponding set of cavities 30 configured to receive the protrusions 20. It is noted that in some cases, the protrusions may be shaped such that the spaces in between the protrusions 20 form the corresponding cavities. However, it is preferable that the cavities be recessed into the panel, as these recessed cavities 30 provide additional support to the protrusion as the covering lip reduces the risk of the protrusion breaking should weight be placed onto the connections between the panels. In the preferred embodiment, the protrusions 20 have a dovetailed shape such that the end of the protrusion is wider than the center as this wider end forms ridges that can grip the walls of the cavity 30, thereby reducing the risk of the panels separating.

Figure 2 depicts the base, or bottom side of the example panel 10. This side of the panel includes a plurality of recesses 50 that are configured to house the joists or other support structures that lay along the base of the roof structure. It is noted that in roof construction the joists have a standard size and spacing depending on the type of joist being used. To this end, the panels will include an irregular pattern of recesses where there will be a mixture of large and small raised sections or protrusions70, 71 between the recesses. This pattern is formed by overlapping the recesses needed for the different standards of joist spacings. In some cases, the different recess patterns may be positioned perpendicular to each other to make aligning the recess easier as the user simply rotates the panel 10 until the recesses 50 aligns with the joists. In some cases, the joist may be positioned in the space between two panels. For such cases, the panel may also include a recessed shoulder 60 around the edge of the panel such that the connection between adjacent panels forms an additional recess.

Once the joists are recessed into the above-mentioned recesses 50, the joist will provide additional support to the panel allowing the panel lay to support more weight without the risk of individual panels breaking. Additionally, the recessed joist can prevent individual panels from sliding while the panels are being placed. This will reduce the risk of panels within the panel layer decoupling during and after installation.

Figures 3 and 4 show another example of the insulating panels 10 which include a plurality of lateral insulated tubes 80,82 that travel through the panel 10, with opening apertures 84 in the side of the panel at each end of these tubes 80,82. It is noted that the tubes 80, 82 will be positioned such that the tube 80,82 in one panel aligns with the tube 80,82 in the adjacent panel. This way the panels can form a consistent tube that extends the length and/or width of the insulating layer across the entire roof space.

During installation, these tubes can be used to house wires or small pipes that travel through the roof space. This ensures that the wires and pipes do not become a trip hazard for any personnel walking over the insulation layer and also ensures that such items do not obstruct the positioning of the insulation panels10.

It is noted that not all of these tubes may be used during construction, therefore the user may need a means to seal the tubes that are not in use to prevent the tubes from forming potential weak points or heat bridges in the insulating layer. In such cases, the panels may be supplied with insulating caps that may be used to seal the openings 84 of the tubes 80,82 thereby preventing airflow through the insulating layer via the tubes 80,82. In other cases, the user may insert an insulating material into the tubes 80,82 to both seal and insulate them, for example, an expanding foam. The user would be able to insert this material by inserting a tube into the aperture 84 at one edge of the insulating layer once the material is pumped into the aperture it will be able to flow through the aligned tubes of the interlocked panels. Note that the user may use the insulating caps to seal the other open apertures to stop the material leaking, and also to isolate the tubes containing wires or pipes as the wires and pipes may be harmed by the material.

It is noted that once this insulating material is inserted it can assist in securing the panels in place. For once the insulated material has hardened, the material will form branches that bridge the gaps between the adjacent panels. These branches will prevent the individual panels from moving laterally and thereby reduce the risk of the panels 10 decoupling.

In some cases, the user may not be able to access the apertures along the edges of the panel layer when the panels 10 have all been placed. In these cases, the panels may include vertical tubes 86 that extend upwards from the lateral tubes 80,82 to the upper surface of the panel. These vertical tubes can be used to insert the insulating material as described above. After which the vertical tube 86 may be sealed with an insulating cap. In some cases, these vertical tubes 86 will be recessed into the panel 10, such that the insulating material of the panel forms a flap or lip that covers the end of the tube 86 to prevent the tube forming a heat bridge through the panel layer.

Figure 5 depicts the cross-section of an example roof space that uses the panels 10 as described above. In this case, the roof space is a loft/attic that includes the panel layer along the base of the space. During construction or after construction of the roof space the user is able to install the panel layer depicted in the figure. More specifically, the user can place an initial panel anywhere within the roof space, then the user can place a second panel adjacent to the first, and couple the panels together by attaching the corresponding interlocking features on the adjacent panels 10. The user can simply repeat this step with each panel 10 until the layer is complete. However as can be seen in the figure the panels may leave a space under the joists within the roof space, and due to building standards, the user is required to leave a gap along the edge of the roof structure to allow airflow into the roof space for ventilation. However, this airflow may lead to drafts that can allow heat from the building to escape. To help prevent these problems the user may place a second layer of panels 10 under the joists, note these panels would be inverted so that the recesses 50 face upwards towards the joists. Alternatively, as shown in the figure the user may use an air-porous insulating material 100, such as fiberglass mats in conjunction with the panels 10.

Wherein this other insulating material would still allow air to flow around it while covering the spaces in the roof structure that cannot be covered by the panels 10.

Once the panel layers have been placed the user can decide to fasten one or more of the panels into place thereby preventing the fastened panels from moving to help secure those panels and the panels adjacent to it in place. It is noted that the panels may include indicia on the top surface to indicate to the user where the fasteners need to be inserted so as to pass into the recessed joist without rupturing the tubes 80,82,86 within the panel. It is noted that there are different types of suitable fasteners but the preferred option would be to use self-drilling insulation screws and insulating washers, as these would insulate the holes made in the panel after they have been inserted. 1. 2. 3. 4. 5. 6. 7. 8.

Claims (18)

1. Claims A method of installing paneled roof insulation, the method comprises: Positioning a first panel into the roof space; Setting a further panel adjacent to the first panel; Interlocking the first and second panels via interlocking features along the edges of the panels; Repeating the process for a plurality of panels until the roof space is covered.
2. The method of claim 1, further comprising the step of using guidelines on the panel to cut the panels into smaller pieces, coupling the smaller pieces to the edges of the panel layer, via the interlocking features, to cover spaces too small for a whole panel.
3. The method of claims 1 and 2 further comprises the step of using the guidelines on the panel to cut apertures into the panel to house features that raise out of the floor of the roof space.
4. The method of any preceding claim further comprises fastening one or more of the panels within the panel layer in place by inserting a suitable fastener through the panel to be fastened and the roof joist or support structure under the panel.
5. The method of any preceding claim further comprises the step of aligning a recess in the base of the first panel with the joist of the roof space; Placing the first panel such that the joist is recessed into the recess of the panel.
6. The method of any preceding claim, wherein the panels include tubes interlocking tubes that run through the length of the panels, further comprising running wires in the roof space through a tube within one or more panels within the panel layer.
7. The method of claim 6 further comprising the step of sealing the empty tubes in the panel layer using a seal cap and/or a sealing material, such as insulating foam, inserted into the tubes.
8. The method of claim 7, wherein the panel includes vertical tubes, the user inserts the sealing material into the tubes via the vertical tube, before sealing the tubes with a cap or flap of insulation.
9. 9. The method of any preceding claim, further comprising laying air porous insulating material around the edges of the insulating panel layer.
10. 10. Insulating panels for performing the method of claims 1-9, wherein each panel comprises a planar panel formed from an insulating material, wherein the edges of the panel comprise at least one interlocking feature, wherein the panel can be coupled to an adjacent panel using the interlocking features of each panel.
11. 11. The panel of claim 10, wherein the top surface of the panel includes guidelines regularly spaced over the surface of the panel.
12. 12. The panel of claims 10 and 11, wherein the base of the panel includes a recess for receiving the joists of the roof structure.
13. 13. The panel of any preceding claim wherein the panels include a metallic reflective layer over the top and/or base of the panel.
14. 14. The panel of any preceding claim wherein the panel further comprises tubes that extend laterally through the panel, such that when the panels are interlocked the tubes are also interlocked.
15. 15. The panel of claim 14, wherein the panels further comprise vertical tubes that extend from the lateral tubes to the top surface of the panel.
16. 16. The panel of claims 14 and 15 further comprises a plurality of insulating caps configured to seal the tubes in the panel.
17. 17. The panels of any preceding claim, wherein the panel further comprises a plurality of fasteners configured to fasten the panel to the roof structure, and wherein the top side of the panel includes indicia to indicate where to insert the fasteners.
18. 18. The panel of claim 17, wherein the fasteners comprise self-drilling insulation screws and insulating washers.