Abstract:
A thermal break clip for securing insulation between two construction surfaces, and preventing thermal bridges. In another aspect, a method for securing insulation between two construction surfaces. In yet another aspect, an insulation system is disclosed.

Description:
[0001]    The instant application claims benefit of prior U.S. Provisional Application Ser No. 61/251,791 filed on Oct. 15, 2009. 
     
    
     BACKGROUND 
       [0002]    U.S. Patent Application No. 20040128930A1 discloses a heat insulating wall structure in which a cold (thermal) bridge is prevented by reducing heat conduction to a metal framework and the rust of the framework and internal dew condensation can be prevented. 
         [0003]    U.S. Pat. Nos. 6,523,324 and 6,698,157 each disclose insulated panels for building systems. 
         [0004]    U.S. Patent Application No. 20040111997 discloses a foam wall panel system with a Z-shaped wall panel connection device. The Z-shape of the wall panel connection device provides cavities on each side which accept the angled edges of foam wall panels that fit within the cavities. Adjacent foam cores having angled edges are secured into the cavities on opposite sides of Z-shaped wall panel connection devices to form a continuous foam wall. 
         [0005]    U.S. Pat. No. 5,758,464 discloses a plurality of insulating panels for installation between and insulation of the metal furrings of a wall system. Preferred panels have a plastic foam core. The vertical side edges of the panels are provided with kerfs for enclosure of the metal furrings and reduction of the thermal bridging conventionally caused by the furrings. 
         [0006]    U.S. Patent Application No. 20060185301 discloses a tie clip used to hold a plurality of preformed insulated concrete forms together. The tie clip could be a definite length of nine gauge high carbon hanger wire comprising a front portion, a rear portion, a front bend, a middle bend, and a rear bend. 
       SUMMARY 
       [0007]    Attachment of insulation to building structures often suffers from thermal bridges, which conduct hot or cold air through the insulation, and thus, lead to loss of thermal efficiency of the insulation. 
         [0008]    In one aspect, there is provided a thermal break clip for securing insulation between a first construction surface and a second construction surface, the thermal break clip attached to the first and second construction surfaces, wherein the thermal break clip is constructed of non-heat conducting material. A thermal heat clip may be conducted of plastic. Insulation may consist of thermal insulation boards. 
         [0009]    In addition, a thermal break clip may have: a first portion; second portion; and a central portion, wherein the first portion attaches to the first construction surface, the second portion attaches to the second construction surface; the first and second portions are joined through the central portion; and the insulation is positioned between the first and second portions. Furthermore, the second portion may be substantially parallel to the first portion, and the central portion may be substantially perpendicular to the first and second portions. In addition, the first portion may extend in the same or opposite direction of the second portion relative to the central portion. Or, the first portion may extend above a plane defined by the central portion; while he second portion may extend both above and below the plane. In the latter case, the insulation is positioned both above and below the plane defined by the central portion. The first portion or the second portion may be flexibly attached to the central portion. It is possible for the central portion to include a plurality of steps, each step substantially perpendicular to the first and second portions. 
         [0010]    A thermal break clip may be attached to the first construction surface or the second construction surface with a perforation means (such as, but not limited to, screws, nails and the like). Or, a thermal break clip may be attached to the first construction surface or the second construction surface with an adhesive. 
         [0011]    In a further aspect, there is provided a thermal break clip for securing insulation between a first construction surface and a second construction surface, the clip having a first leg; a second leg; and a central portion; the first leg substantially parallel to the second leg; the central portion substantially perpendicular to the first and second legs; the first leg and second leg extending above a plane defined by the central portion; the first leg attached to the first construction surface; the second leg attached to the second construction surface; the insulation positioned between the first and second legs, wherein the clip is constructed substantially of non-heat conducting material. The insulation may consist of thermal insulation boards. 
         [0012]    In yet another aspect, there is provided a thermal break clip for securing insulation between a first construction surface and a second construction surface, the clip having a first leg; a second leg; and a central portion; the first leg substantially parallel to the second leg; the central portion substantially perpendicular to the first and second legs; the first leg extending above a plane defined by the central portion; the second leg extending above and below the plane; the central portion having one or more steps, each step substantially perpendicular to the first and second legs; the first leg attached to the first construction surface; the second leg attached to the second construction surface; the insulation positioned between the first and second legs both above and below the plane, wherein the clip is constructed substantially of non-heat conducting material. The insulation may consist of thermal insulation boards. 
         [0013]    In yet a further aspect, there is provided a method of securing insulation between a first construction surface and a second construction surface, the method comprising: a) attachment of a plurality of base thermal break clips to the first construction surface, each base thermal break clip having an opening to receive the insulation; b) positioning a first portion of the insulation into a subset of the plurality of base thermal clips; c) positioning of a plurality of intermediate base clips onto the first set of insulation, each of the intermediate thermal break clips having a first and second opening for receiving insulation, and each intermediate thermal break clip being attached to the first construction surface; d)positioning of a second portion of insulation onto the second openings of the intermediate thermal break clips; e) repetition of steps c and d until the first construction surface is substantially covered by the insulation; and attachment of the second construction surface to the plurality of base and intermediate thermal break clips; wherein the base thermal-break clips and intermediate thermal-break clips are constructed of non-heat conducting material. Examples of a first construction include, but are not limited to, a concrete wall; a metal deck; a drywall board; and vertical strapping attached to wood siding. Examples of a second construction surface include, but are not limited to, wood studding, a drywall board and a fibre board. 
         [0014]    Alternatively, a second construction surface may be brick cladding, with an air gap present between the thermal break clips and the brick cladding. 
         [0015]    In yet another aspect, there is provided an insulation system comprising: a plurality of base thermal-break clips, a plurality of intermediate thermal-break clips; a plurality of insulation boards; a first construction surface and a second construction surface, the base and intermediate thermal-break clips being constructed of non-heat conducting material, wherein: the insulation boards are paired and ship-lapped; the intermediate thermal-break clips connect adjacent pairs of ship-lapped insulation; the paired insulation boards are positioned into each of the plurality of base thermal-break clips; the intermediate and base thermal-break clips are attached to the first construction surface, thereby securing the plurality of insulation boards to the first construction surface; and the construction surface is attached to the intermediate and base thermal-break clips. 
     
    
     
       BRIEF DESCRIPTION OF FIGURES 
         [0016]      FIG. 1  illustrates a perspective view of a first embodiment. 
           [0017]      FIG. 2  illustrates a perspective view of a second embodiment. 
           [0018]      FIG. 3  illustrates a sectional view of a first application of a thermal break clip. 
           [0019]      FIG. 4  illustrates a sectional view of a second application of a thermal break clip. 
           [0020]      FIG. 5  illustrates a sectional view of a third application of a thermal break clip. 
           [0021]      FIG. 6  illustrates a sectional view of a fourth application of a thermal break clip. 
       
    
    
     DESCRIPTION OF EMBODIMENTS 
       [0022]    Referring to  FIG. 1 , a first embodiment of a thermal clip ( 10 ) is shown with a first ( 15 ) and second ( 20 ) leg joined through a central portion ( 25 ). The first leg ( 10 ) has an aperture ( 30 ) along its length, for reception of a screw (not shown), nail (not shown), or similar attachment means. The first leg ( 15 ) is attached to a first construction surface (not shown). 
         [0023]    The legs ( 15 ,  20 ) can have equal or unequal height. In the embodiment illustrated in  FIG. 1 , the height ( 35 ) of the second leg ( 20 ) is less than the height ( 40 ) of the first leg ( 15 ). This allows for use of a tool (for example, but not limited to, a screw gun, hammer, etc) for securing the attachment means (not shown) through the aperture ( 30 ). As such, the height ( 35 ) of the second leg lies below the aperture ( 30 ) to allow for use of an application tool (not shown). 
         [0024]    In addition, the second leg may also have an aperture, for attachment to a second construction surface. It is also understood that each leg of the thermal clip can include one or more apertures. 
         [0025]    Alternatively, a thermal clip of the instant application can be attached using means that do not require an aperture. An example of means is, but not limited to, an adhesive. In a case where an adhesive is used to secure a leg to a construction surface, there is no aperture in such leg of the thermal clip. 
         [0026]    The length ( 45 ) of the central portion ( 25 ) is at least equal to the width of insulation (not shown) used. The width ( 50 ) of the thermal clip is not limited to any particular range. As an example, where insulation boards are used, the width ( 50 ) of the thermal clip ( 10 ) is at least equal to the total thickness of the insulation boards used. 
         [0027]    The second leg can be flexibly attached to the central portion, so that the second leg can be folded out (in a direction away from the first leg), to allow for insulation to be installed within the clip. The second leg can then be folded back to its original position. 
         [0028]    Alternatively, the central portion ( 25 ) may be staggered, rather than planar, to accommodate a staggered arrangement of insulation. As an example, the insulation can consist of a plurality of insulation boards that are ship-lapped. 
         [0029]    The insulation is positioned in the opening defined by the two legs ( 15 ,  20 ) and the central portion ( 25 ). 
         [0030]    Referring to  FIG. 2 , a second embodiment of a thermal clip ( 60 ) is shown with a first ( 65 ), second ( 70 ) and third ( 75 ) legs joined through a central portion ( 80 ). The first leg ( 60 ) has an aperture ( 85 ) along its length, for reception of a screw (not shown), nail (not shown), or similar attachment means. The first leg ( 65 ) is attached to a first construction surface (not shown). In this embodiment, insulation is positioned in both of the openings; i.e. the thermal break clip abuts between two pieces of insulation. One opening is defined by the legs ( 65 ,  70 ) and the central portion ( 80 ). The other opening is defined by the leg ( 75 ) and central portion ( 80 ). 
         [0031]    The first and second legs ( 65 ,  70 ) can have equal or unequal height. In the embodiment illustrated in  FIG. 2 , the height ( 90 ) of the second leg ( 70 ) is less than the height ( 95 ) of the first leg ( 65 ). This allows for use of a tool (for example, but not limited to, a screw gun, hammer, etc) for securing the attachment means (not shown) through the aperture ( 85 ). As such the height ( 90 ) of the second leg lies below the aperture ( 80 ) to allow for use of an application tool (not shown). 
         [0032]    The third leg ( 75 ) is generally aligned with the second leg ( 70 ), and extends below the central portion ( 80 ). The third leg can be used to secure or hold insulation from below. In addition, the third and second legs can be combined into one continuous leg, extending both above and below the central portion ( 80 ). 
         [0033]    In addition, the second and third legs may each have one or more apertures, for attachment to a second construction surface. It is also understood that each leg of the thermal clip can include one or more apertures, as needed. 
         [0034]    Alternatively, a thermal clip of the instant application can be attached using means that do not require an aperture therein, such as, but not limited to, an adhesive. In such case, where an adhesive is used to secure a leg to a construction surface, there is no aperture in such leg of the thermal clip. 
         [0035]    Another embodiment of a thermal clip of the instant application (not shown) is a variation of the embodiment shown in  FIG. 1 . The second leg, rather than being on the same side as the first leg relative to the central portion, is on the opposite side relative to the central portion. This type of arrangement is also known in the art as a butt joint. 
         [0036]    In  FIG. 2  central portion ( 80 ) is shown with a step-type geometry, for use with insulation, such as insulation boards that are staggered (or ship-lapped). The embodiment shown in  FIG. 2  is for use with two insulation boards, and therefore, the central portion ( 80 ) has two steps, one for each insulation board (not shown). The width of each step ( 97 ,  98 ) is at least equal to the thickness of each insulation board. The height ( 99 ) of the step is at least equal to the offset distance of the ship-lapped boards. While a step-type geometry is shown in  FIG. 2 , the central potion can also have a planar geometry (as in  FIG. 1 ), for board insulation that is stacked aligned, rather than staggered (or ship-lapped). 
         [0037]    The central portion can be designed to hold a plurality of insulation boards. 
         [0038]    The width ( 100 ) of the thermal clip is not limited to any particular range. 
         [0039]    The thermal clip ( 60 ) illustrated in  FIG. 2  is made of material that does not conduct heat, such as, but not limited to, plastic, recycled plastic, propylene, and the like. 
         [0040]    A method of securing insulation between two construction surfaces is as follows:
       1) One or more insulation boards are secured to an edge of the first wall using a plurality of thermal break clips with the general shape as shown in  FIG. 1  (with or without apertures). These thermal break clips are attached to the wall surface, and, optionally to any adjacent structural surface (e.g. a base or floor, or adjacent wall).   2) Insulation boards are then positioned into the openings of the attached thermal clips. Further boards are attached to an adjacent set of insulation boards using a plurality of thermal clips with the general shape as shown in  FIG. 2  (with or without apertures). These thermal clips may be referred to as intermediate thermal break clips. The intermediate thermal break clips are attached to the wall surface. Installation of the insulation boards continues until the wall is covered with insulation.   3) A second construction surface is then applied and secured to the insulation/thermal break structure, so that insulation is now between the wall and the construction surface.       
 
         [0044]      FIGS. 3 to 6  provide examples of using a thermal break clip to secure insulation in a number of settings. 
         [0045]      FIG. 3  illustrates a concrete wall application of a thermal break clip ( 125 ), for securing insulation ( 110 ) between a concrete wall ( 115 ) and drywall ( 105 ). The insulation ( 110 ) is ship-lapped, and consists of two insulation boards. The thermal break clip ( 125 ) is secured to the drywall ( 105 ) with a drywall screw ( 120 ), and secured to the concrete wall ( 115 ) with a screw ( 130 ). 
         [0046]      FIG. 4  illustrates a brick wall application of a thermal break clip ( 150 ), for securing insulation ( 145 ) between exterior brick cladding ( 165 ) and wood studding ( 140 ). The insulation ( 145 ) is ship-lapped, and consists of two insulation boards. The thermal break clip ( 150 ) is secured to the wood studding ( 140 ) with a first screw ( 170 ), and secured to the brick cladding ( 165 ) with a galvanized brick tie ( 160 ). There is a layer of space ( 155 ) between the secured insulation ( 145 ) and the exterior brick cladding ( 165 ). The thermal break clip ( 150 ) is further secured to the insulation ( 145 ) through the perforation attachment means ( 175 ). 
         [0047]      FIG. 5  illustrates a roof application of a thermal break clip ( 200 ), for securing insulation ( 190 ) between a metal roof deck ( 210 ) and a fibre board ( 185 ). The insulation ( 190 ) is ship-lapped, and consists of two insulation boards. The thermal break clip ( 200 ) is secured to the fibre board ( 185 ) with a drywall screw ( 195 ), and secured to the roof deck ( 210 ) with two self-tapping screws ( 205 ). A weatherproof membrane ( 180 ) is placed adjacent the fibre board ( 185 ). 
         [0048]      FIG. 6  illustrates a wood siding application of a thermal break clip ( 265 ), for securing insulation ( 260 ) between wood studding ( 255 ) and vertical strapping ( 270 ) which is adjacent to wood siding ( 275 ). The insulation ( 260 ) is ship-lapped, and consists of two insulation boards. The thermal break clip ( 265 ) is secured to the wood studding ( 255 ) with a first screw ( 280 ), and secured to the strapping ( 270 ) with a second screw ( 285 ). 
         [0049]    While specific embodiments have been described in detail in the foregoing detailed description and illustrated in the accompanying drawings, those with ordinary skill in the art will appreciate that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention, which is to be given the full breadth of the appended claims and any and all equivalents thereof.