Abstract:
An insulated wall assembly including a plurality of pre-cast panels, a plurality of insulation panels, at least two J-shaped clips, and at least one I-shaped clip is provided. The precast panels may be oriented such that the adjacent vertical edges are in an abutting relationship to form a wall, and the J-shaped clips comprise a trough portion and a wall engaging portion. The I-shaped clip comprises two wall engaging portions and a two retention portions, and the wall engaging portions of the J-shaped clips each define a substantially planar wall-engaging surface capable of attaching to the wall. The wall-engaging portions of the I-shaped clip each define a substantially planar wall-engaging surface capable of attaching to the wall. The trough portion of the J-shaped clip comprises at least one pliant integral co-extruded seal extending away from a distal edge of the trough portion in an angled configuration, and each retention portion of the I-shaped clip includes at least one pliant integral co-extruded seal extending away from a distal edge of the retention portion in an angled configuration.

Description:
This application is a continuation-in-part of U.S. application Ser. No. 10/756,002 filed Jan. 13, 2004 now abandoned, which claims the benefit of U.S. Provisional Application No. 60/523,031, filed Nov. 18, 2003. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates to retention clips mountable to wall panels to improve the ease with which these panels can have insulation or related structure mounted thereto. 
     Wall panels are some of the basic components of building structures, and come in various configurations, including pre-formed and assembled-on-site versions. One type of wall panel that has been used extensively in modern building structures involves the use of tilt-up, precast, cast-in-place, and other similar construction techniques, where uncured material (such as concrete) is introduced into a form and cured such that a panel in the shape of the form is produced. As used herein, a precast panel includes any panel that is formed from a cast material that upon curing hardens up, thereby allowing the panel to be subsequently placed in a desired (typically vertical) location within a building structure. A tilt-up panel is a particular type of precast panel that is formed on a horizontal surface and tilted up into place upon curing of the cast material. A need exists for securing insulation to these and related panels in a quick, inexpensive and repeatable fashion. 
     SUMMARY OF THE INVENTION 
     The present invention comprises a clip that includes sealed retention channels, such that when the clips are connected to precast wall panels (generally), tilt-up wall panels (specifically) or any other type of wall or surface to be insulated, they can hold insulation securely to the wall panel in such a way as to maximize the insulative properties of the wall. The clips are configured such that close tolerances, coupled with knife-edge seals, promote a secure fit with the insulation material and improved insulative properties of the wall panel-insulation material combination. The clips of the present invention can be disposed both horizontally and vertically on the wall panel, the former to support the weight of the insulation and the latter to adjoin adjacent insulation panels or enclose the edge of the insulation. 
     According to a first aspect of the invention, a retention clip is disclosed. The clip includes a panel engaging portion and a retention portion, where the panel engaging portion and retention portion together define at least one retention channel between them. The retention portion further includes at least one seal extending along a longitudinal dimension of the retention channel. The seal is configured such that it defines a channel entrance along the retention channel&#39;s longitudinal dimension; this channel entrance defines a throat-like channel access dimension that is smaller (or restrictive) relative to a parallel dimension of a remaining portion of the retention channel. 
     According to another aspect of the invention, a clip for securing insulation to a panel is disclosed. In the present context, it will be understood that insulation comes in various forms, and that any such form that includes rigid sheet or fibrous-based rolls (such as fiberglass) is envisioned as being compatible with the present invention. In addition, any generally planar sheet material with a thickness dimension properly engageable with the clip described herein would qualify as insulation by virtue of its ability to measurably reduce the transfer of heat to or from the panel relative to no sheet being present. The clip includes a panel-engaging portion with a corresponding panel-engaging surface, and a retention portion, configured to engage the insulation, coupled to the panel-engaging portion. The retention portion is made up of numerous walls that together define at least one retention channel, and one or more seals configured such that upon placement of the insulation into the channel, the seal engages the insulation. 
     In one form, the placement of the insulation into the channel causes the seal to be biased against the insulation to effect a secure fit between them. Moreover, the seal can be situated on a substantially distal end of the retention portion. In another option, the panel-engaging surface is substantially planar, while in yet another, the clip is of unitary construction. The panel-engaging portion is elongate relative to the retention portion in at least one dimension such that an attachment-receiving tab is defined therein. The attachment-receiving tab can accept adhesives thereon or fasteners therethrough, such as screws, nails, rivets or the like. In the relatively elongate configuration, the tab extends such that a substantially outward-facing normal projection from a surface on the tab does not intersect the plurality of walls of the retention portion, thereby facilitating substantially unimpeded access of a fastener to the clip to retain the clip on the panel. The tab may additionally include an aperture to facilitate the receipt of a fastener therethrough. 
     The clip can be configured such that the retention portion defines a substantially T-shaped (or I-shaped) cross-section or where the entirety of the clip defines a substantially J-shaped cross-section. In the T-shaped configuration, the plurality of walls define two retention channels, whereas in the J-shaped configuration, they define one channel. In the T-shaped configuration, a seal can be disposed at the substantial distal end of each of the retention portions. In addition, each of the two retention channels of the T-shaped clip are configured to secure substantially equal-sized parts of the insulation. The clip may further include one or more springs disposed along one of the plurality of walls. These springs can be formed in either of both of the panel-engaging portion or the channels. For example, a spring may be disposed along one of the walls that extends substantially parallel to the panel-engaging portion. The T-shaped clip can be made as either a one-piece (unitary) construction, or from multiple-piece construction; in the latter, at least one of the plurality of walls makes up a first piece, while another of the walls makes up a second piece. For the multiple-piece configuration, a locking mechanism may be included to facilitate a snap-fit between the first and second pieces. The locking mechanism may include a plurality of complementary teeth on respective surfaces of the first and second pieces. 
     The clip may be made from a variety of materials, including plastic, such as polyvinyl chloride (PVC) or related extrudable plastics. The seal may be made from a material that is pliant (flexible) relative to the material making up the remainder of the clip. This promotes a more secure fit with reduced likelihood of gap formation, especially when the insulation against which the seal engages is rigid. The position of the seal is such that when the insulation is placed within the clip, the seal is biased against the insulation, substantially eliminating the aforementioned gap and consequent airflow between the seal and insulation. In situations where the seal is made from a different extrudable material than the remainder of the clip, it may be configured such that it can be co-extruded with a corresponding one of the walls. 
     According to another aspect of the invention, an insulative assembly is disclosed. The assembly includes a panel, a layer of insulation configured to cover at least a portion of the panel, and first and second clips to secure the insulation to the panel. The first clip includes a first panel-engaging portion and a first retention portion coupled to the first panel-engaging portion similar to those described in the previous aspect. The second clip includes a second panel-engaging portion and a second retention portion, also similar to that previously described. Optionally, and as before, the panel is substantially planar. In addition, the first clip can be made substantially J-shaped, while the retention portion of the second clip can be made substantially T-shaped. At least one of the first clips can be attached to the panel such that its longitudinal dimension extends along a substantially horizontal dimension of the panel. In such case, two of the first clips can be placed such that one is disposed above the other on the panel. Moreover, the retention channels of the two first clips may be disposed in a facing relationship to one another, thereby forming a frame-like enclosure at the upper and lower end of the insulation. In addition, the first clips can also be placed with its longitudinal dimension along a substantially vertical dimension of the panel; such use of the first clips can promote lateral support of the insulation, especially in corners or endwalls formed by the panels. At least one of the second clips can be disposed on the panel with its longitudinal dimension along a substantially vertical dimension of the panel. In another option, the thickness of the second clip is slightly less than the first clip, thereby allowing the former to fit inside the latter. 
     According to yet another aspect of the invention, a method of forming an insulated panel is disclosed. The method includes providing a panel, attaching at least one clip to the panel, and placing insulation in a retention channel of the clip such that the insulation engages a seal defined in the channel. As previously discussed, the clip includes a panel-engaging portion defining a panel-engaging surface thereon and a retention portion coupled to the panel-engaging portion and configured to engage the insulation. By placing the insulation in the clip, a bias is effected between the seal and the insulation such that a secure fit between the two is formed. Also as previously discussed, the clip can be secured to the panel by adhesive, fasteners or related attachment schemes. As with the previous aspect, numerous clips may be used to secure the insulation to the panel. For example, the plurality of clips may include at least one substantially J-shaped clip and at least one clip with a substantially T-shaped retention portion. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       The following detailed description of the preferred embodiments of the present invention can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which: 
         FIG. 1  illustrates a side view of an embodiment of a first clip according to an aspect of the present invention; 
         FIG. 2  illustrates the clip of  FIG. 1  mounted to a wall panel and supporting a piece of insulation material; 
         FIG. 3A  illustrates a top view of an embodiment of a second clip; 
         FIG. 3B  illustrates a top view of an alternate embodiment of the second clip of  FIG. 3A ; 
         FIG. 4  illustrates an exploded view of the second clip of  FIG. 3B ; 
         FIG. 5  illustrates a wall panel with an insulation sheet mounted to it using both the first and second clips according to an aspect of the present invention; and 
         FIG. 6  illustrates a variation on the second clip depicted in  FIG. 3A , including springs disposed in various channel walls. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring first to  FIG. 1 , a clip  100  is substantially J-shaped such that it can support a workpiece (such as a piece of insulation) against a wall or related panel. Clip  100  defines a retention portion  110  (also known as a trough) to engage the workpiece, and an extending panel-engaging portion  120  for engagement of the support clip  100  to the wall. Retention portion  110  is made up of walls  112 ,  114  and connected to a portion of panel-engaging portion  120  at a proximal end  116  of retention portion  110  to define a retention channel  110 A therebetween. The panel-engaging portion  120  extends beyond retention portion  110  with an extension  127  to facilitate connection of clip  100  to a wall surface. The elongate nature of the panel-engaging portion  120  with extension  127  is such that a user can easily insert a fastener  1  (such as a screw, nail, wall anchor, rivet or the like) through an optional aperture  125  defined in extension  127 . Preferably, clip  100  is of one-piece construction, and is made of an easily-formable material, such as plastic. More preferably, the plastic is an extruded plastic. A seal  130  is disposed at the distal end of the trough, as shown by the end of wall  112  such that when the workpiece is placed inside retention channel  110 A, the workpiece forms a close fit with the panel-engaging portion  120 , the lower wall  114 , and the edge formed by the seal  130 . The seal  130  promotes a relatively tight fit between the workpiece and the clip  100  so that the flow of air between the workpiece and the generally planar surface to which the clip is mounted is significantly reduced. Efficacy of the seal  130  is enhanced when the workpiece is generally planar and relatively rigid. In a preferable (although not necessary) form, seal  130  is made of a material that is more pliant than that of the remainder of clip  100 . For example, both could be made of plastic, where the plastic of seal  130  is more flexible than that of the panel-engaging portion or the remainder of retention portion  110 . Clip  100  includes a substantially constant cross-section, such that it is amenable to rapid, low-cost production techniques, including extrusion. The seal  130  may be made from the same material as the remainder of clip  100 , or made from a different material such that the two can be co-extruded. 
     Regardless of the nature of the material used to form the seal  130 , the seal  130  is configured such that it defines a restricted channel entrance  132  along a longitudinal dimension of the retention channel  110 A. More specifically, as is clearly illustrated in  FIG. 1 , the channel entrance  132  defines a channel access dimension a that is restricted relative to a parallel dimension b of a remaining portion of the retention channel  110 A, such that (b-a) represents an extension distance t 1  of the seal  130  which, as is illustrated in  FIG. 2 , exceeds the spacing S that is defined between the insulation  300  and the wall panel  400 . The I-shaped and T-shaped clips described below also define corresponding extension distances t 2  that exceed the spacing s, as is clearly illustrated in  FIGS. 3A ,  3 B,  4 , and  6 . The insulative characteristics of a sheet of insulation held by the clip  100  are thus enhanced because the seal either defines a discrete contact surface with the insulative sheet or at least restricts the size of any gap between the clip  100  and the insulative sheet at the channel entrance  132 . 
     Referring next to  FIG. 2 , the relative engagement of insulation  300 , support clip  100  and the wall panel  400  is shown, where the wall panel  400  is shown in a preferably vertical orientation. The connection between the clip  100  and wall panel  400  can be by any known means, such as adhesives or fasteners. In the event a fastener is used, the relatively exaggerated surface of panel-engaging portion  120  provides a suitable location through which the fastener may be placed. Seal  130  is preferably oriented such that defines a knife-edge along the seal&#39;s longitudinal dimension. As can be seen from the figure, the size of the clip  100  relative to the insulation  300 , as well as the inwardly-projecting seal  130  is such that seal  130  forms a snug fit against a corresponding surface of the insulation  300 . This snug fit further improves the insulative properties of the wall/insulation combination, as it cuts down on airflow around the insulation  300  that could otherwise lead to drafting and related circulation problems. By having the seal  130  be relatively compliant, it can be more conformally shaped against the insulation  300  to further reduce the likelihood of formation of gaps or related airflow passages. Support of insulation  300  along a downward direction is provided by trough  110 , specifically its lower wall  114 . Referring to  FIG. 5 , as clearly illustrated in the Figure, the plurality of insulation panels  300  have a major surface parallel to a surface of the wall  400 . 
     Referring next to  FIGS. 3A ,  3 B and  6 , variations  200  and  250  on a second clip are shown. Referring with particularity to  FIG. 3A , one variation defines a substantially T-shaped retention portion  210  made up of a pair of retention channels  210 A,  210 B. In this variation, the clip  200  comprises a unitary structure where retention portion  210  is integrally formed with an elongate panel-engaging portion  220  along an S-shaped spring  240 . In the present context, a structure is considered “unitary” when it is of one-piece construction. By way of example, a one-piece molded or extruded plastic component would be considered to exhibit unitary construction. Similarly, if the part includes co-extruded seals  230 A,  230 B (collectively seals  230 ), it is still of unitary construction, as the finished part has no components that are separately attached after the forming process. The inclusion of spring  240  allows the retention channels  210 A,  210 B to be elastically bent during insertion of the insulation, then snapped back into place afterwards. As with the J-shaped support clip  100 , seals  230  disposed at the ends of each respective channel  210 A and  210 B are used to facilitate a snug fit between the insulation (not presently shown) and the clip  200 . In addition, panel-engaging portion  220  includes an extension  227  that forms a base that can be mounted to a wall panel in a manner similar to that of support clip  100 . Referring with particularity to  FIG. 6 , a further variation is shown on the unitary construction of the second clip, where panel-engaging portion  520  together with retention portion  510  (defined by channels  510 A,  510 B) makes up clip  500 . In addition to previously shown and described spring  240  (shown presently as spring  540 A) disposed on a generally vertical wall of retention portion  510 , a second spring  540 B is included on the generally horizontal wall that carries the and seals  530 A,  530 B. The addition of the second spring  540 B provides additional clip compliance, further enabling insertion of a layer of insulation into the channels  510 A,  510 B. 
     Referring with particularity to  FIG. 3B , another variation  250  of the second clip is substantially I-shaped such that it defines a retention portion  260  made up of a pair of retention channels  260 A,  260 B. Unlike the unitary construction of clip  200 , adjoining clip  250  is of two-piece construction, where connection  290  between them is defined by a T-shaped male member  294  that can be secured to a substantially T-shaped female member  292 . Panel-engaging portion  270  of female member  292  defines a base that is mountable to the surface of the wall panel (not presently shown). As with the previously-discussed variation, clip  250  includes seals  280  (shown corresponding to each respective channel as  260 A and  260 B) that are used to facilitate a snug fit between the insulation (not presently shown) and clip  250 . Referring to  FIG. 5 , as clearly illustrated in the Figure, the co-extruded seals (not shown) of the I-shaped clip  250  engage a major face of the plurality of insulation panels  300 . 
     Referring next to  FIG. 4 , the engagement of retention channels  260 A,  260 B to the panel-engaging portion  270  for clip  250  is shown. While the insertion of male member  294  into female member  292  could be effected by various means (such as a frictional pressing into place of the former to the latter), a more permanent connection can be established by using numerous prismatic retention members  293  disposed on corresponding surfaces of the members  294 ,  292  such that the prismatic retention members  293  are configured to define complementary snap-fit connection surfaces. The prismatic retention members  293  would resist separation from the complementary engaging surface once joined. Prismatic retention members  293  could be made from any suitable shape, of which triangular, saw-tooth or trapezoidal forms are examples. Preferably, but not necessarily, the relationship between the prismatic retention members  293  is such that a permanent lock can be formed. In the present context, a locking arrangement is considered “permanent” where the connection between two members is such that they cannot be separated without severely curtailing or disabling their subsequent connective properties. 
     Examples of dimensions of the clips  100 ,  200  and  250  (of which the latter is shown in  FIG. 4 ), while capable of being adapted to any predetermined size (based on the application), are described in conjunction with  FIG. 4 . Overall width W 1  of the top of the retention portion  260  is approximately two inches, with an overall height H 1  of approximately seven-eights of an inch. The overall height H 2  of the male member  294  is approximately thirteen-thirty seconds of an inch with the height H 3  of each individual prismatic retention member  293  approximately three thirty-seconds of an inch. Furthermore, each individual prismatic retention member  293  has a width W 2  of approximately three thirty seconds of an inch at its outer dimension, and a width W 3  of approximately one-sixteenth of an inch at its inner dimension. The top of the retention portion  260  is angled A 1  relative to a horizontal plane by approximately one degree. Seals  280 A,  280 B are angled A 2  relative to the same horizontal plane by between one hundred and thirty five and one hundred and forty degrees. Height of the seals  280 A,  280 B is approximately five thirty-seconds of an inch, and includes an approximately thirteen degree taper angle A 3  with a thickness at its narrow end of approximately one-thirty second of an inch. The panel-engaging portion  270  has an overall height H 4  of approximately one and one-thirty second of an inch, with a thickness B of the horizontally-oriented base  271  of approximately one-sixteenth of an inch. The outer dimension width W 3  of the female member  292  is approximately three-sixteenths of an inch, with an inner dimension width of the portion that receives the prismatic retention members  293  ranging from approximately one-sixteenth of an inch for the inner dimension W 4 , to approximately three-thirty seconds of an inch for the outer dimension W 5 . The angle A 4  with which the opening of female member  292  makes with the horizontal plane is between sixty-five and seventy degrees, shown specifically in the figure as approximately sixty-nine degrees. 
     Referring to  FIG. 5 , in conjunction with  FIGS. 1 ,  3 A and  3 B, it will be appreciated that the relative thickness dimensions T 1  of first clip  100  and T 2  of second clips  200 ,  250  is such that T 1  is slightly greater than T 2 . Thus, in placing the clips onto wall panel  400 , the second clips  200 ,  250  can be placed within first clip  100 . The flexible nature of the material (such as the aforementioned PVC) making up clips  100 ,  200  and  250  facilitates the relative overlapping relationship between the clips. It will also be appreciated that while first clips  100  are shown in a generally horizontal orientation, they are also suitable for generally vertical mounting as shown such that they can substantially enclose the vertical edge of the insulation  300  that would otherwise be left exposed. 
     Referring to  FIG. 5 , as clearly illustrated in the Figure, the trough of one of the J-shaped clips  100  is provided on a bottom portion of the plurality of insulation panels  300  and the trough of another one of the J-shaped clips  100  is provided on a top portion of the plurality of insulation panels  300 . A side portion of the insulation panel  300  is provided within one retention portion of the I-shaped clip  250 . In one configuration, both ends of the I-shaped clip  250  extend vertically into the opposing trough portion of the at least two J-shaped clips  100 . 
     Referring to  FIG. 5 , as clearly illustrated in the Figure, the co-extruded seal  130  of the J-shaped clips  100  engage the major face of the plurality of insulation panels  300 . 
     Having described the invention in detail and by reference to preferred embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. More specifically, although some aspects of the present invention are identified herein as preferred or particularly advantageous, it is contemplated that the present invention is not necessarily limited to these preferred aspects of the invention.