Abstract:
An adjustable insulation containment apparatus for insulating about duct work having a plurality of foldable sections or members that can be selectively ganged together by connection to each other to make a run. The members can be adjusted for width of the conduit. Alternatively, the apparatus can be formed by a pair of scored planar sheets held in position by end panels and spacers.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The present invention is directed to an adjustable apparatus that can be readily assembled for placement about a ventilation duct in an attic or the like for containing insulation in a preferred configuration about the duct, and is adjustable to accommodate various configurations of ductwork. 
         [0002]    Because energy is becoming an increasingly scarce and expensive resource for both the heating and cooling of houses and similar structures, it is becoming increasingly important to insulate such structures in such a manner so as to prevent significant loss of heating and cooling to the ambient air. Current recommended insulation guidelines typically call for an insulating factor in the R30 to R38 range. An insulating factor of R38 effectively equates to about 12 inches of blown cellulose or fiberglass insulation. Consequently, most modern houses are constructed with approximately 12 inches of insulation within the attic structure above the ceiling of the top floor. 
         [0003]    In addition to energy lost through walls and ceilings, there can also be a substantial loss of energy through the ductwork that carries heating and/or cooling throughout a structure. In order to avoid such a loss, this ductwork is often placed beneath the ceiling or between a lowered artificial ceiling and the attic in such a structure. Nevertheless, many structures do not have sufficient clearance to place the ductwork in a protected location, and even when the ductwork can be placed below the ceiling, it is often aesthetically unpleasing. 
         [0004]    Consequently, the ductwork is often placed in the attic, especially when no basement is present to carry it. When such ductwork is placed in an attic, it is usually placed over ceiling joists and is typically 6 inches or greater in diameter or thickness. When insulation is blown into the attic, it settles into the space between the joists and below the ductwork and only partially covers the ductwork. Consequently, it is desirable to also fully insulate the ductwork that is run through the attic with a 12-inch layer of insulation. 
         [0005]    While it is desirable to provide a full layer of insulation for the ductwork, it would be prohibitively expensive to place an insulating blanket of sufficient thickness to provide 12 inches of insulation for the ductwork throughout the entire attic and it may also make it difficult to work in the attic for people needing access thereto. Therefore, it is desirable to provide a structure that retains additional insulation in the region immediately surrounding the ductwork so that the ductwork can have a proper insulating cover without spreading the insulation in a uniform layer throughout the attic. 
         [0006]    Structures for containing insulation in this manner have previously taken the form of a fixed wall that is constructed with material such as boards and plywood and nailed to the ceiling joists to form a trough for the insulation covering the ductwork. While such a constructed wall is effective in maintaining the insulation, it has a major drawback in that it requires a substantial period of time, labor, and materials to construct. Most insulators are interested in maintaining labor costs as low as possible and wish to quickly apply the appropriate insulation coating to an attic. 
         [0007]    Consequently, it is desirable to have an apparatus that utilizes relatively simple and inexpensive materials and includes component structures for accommodating different types, lengths, and configurations of ductwork to provide containment for insulation covering the ductwork. 
       SUMMARY OF THE INVENTION 
       [0008]    A containment apparatus is provided for use in conjunction with the insulation of ventilation ducts in attics and the like wherein the apparatus is readily and quickly assembled for holding or containing insulation in a surrounding relationship about the duct. In one embodiment the apparatus comprises a plurality of foldable members that form an adjustable insulation containment apparatus. Each member is folded to form three sides of a containment cell, and multiple members are slidably interlocked to form an elongate channel having a series of segmented compartments that can be filled to the top thereof with insulation. 
         [0009]    The number of members used will depend on the length of the ductwork being insulated, thereby providing an apparatus that can accommodate essentially any typical configuration of ductwork. Preferably, the apparatus is constructed of a cardboard type of material wherein the corrugation of the members is generally vertically aligned to provide flexibility and allow bending about a vertical axis along the member. 
         [0010]    During installation, the desired number of members can be quickly deployed to a fully expanded configuration and positioned over a duct, after which the apparatus is filled with insulation to provide suitable insulation for the duct. The members are formed to fold at selected positions to accommodate round ducts or different sizes of rectangular ducts. Scores or weakened areas are provided, so that portions of the members may also be removed to accommodate different sizes of rectangular ducts. Preferably, the apparatus is sized and shaped so that when installed and filled with insulation, it provides the duct with a desired insulation factor. 
         [0011]    In an alternative embodiment, the adjustable channel is constructed from scored and folded foam sheeting which is unfolded to form elongate planar panels or sheets with end panels of the type described for the embodiment previously described above and held in place by crossing elements or spans. 
       OBJECTS AND ADVANTAGES OF THE INVENTION 
       [0012]    Therefore, the objects of the present invention are: to provide an insulation containment apparatus for holding insulation around and over a ventilation duct so as to provide a selected insulation factor for the ventilation duct; to provide such an apparatus that can be brought to a job site in a collapsed configuration and relatively quickly assembled and adjusted to an expanded configuration suitable for use in conjunction with such a ventilation duct; to provide such an apparatus that includes foldable and compact component members that can be interlocked to form the apparatus; to provide such an apparatus having component members that are easily modified by bending along prescored lines or removing along tear lines to accommodate varying sizes and types of ducts; to provide such an apparatus with side panels that can be constructed of cardboard, foam board, plastic, screen or the like that are suitable for use in building construction and relatively inexpensive in cost; to provide such an apparatus that can be relatively quickly installed; to provide such an apparatus that can be treated to improve fire resistant properties thereof; to provide such an apparatus that is relatively easy to manufacture and inexpensive to produce; to provide a method of use of the apparatus that allows relatively quick and simple construction of a containment apparatus for containing insulation around a duct within an attic or the like; and to provide such an apparatus and method that are particularly well adapted for the intended usage thereof. 
         [0013]    Other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. 
         [0014]    The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]      FIG. 1  is a fragmentary view of an insulation containment member removably joined with a second insulation containment member to form an adjustable insulation containment apparatus in accordance with the present invention shown positioned over a ventilation duct in an attic structure. 
           [0016]      FIG. 2  is a fragmentary view of the adjustable insulation containment apparatus as adjusted to accommodate a ventilation duct that is rectangular in manufacture and showing an insulation containment member positioned to be joined with another insulation containment member. 
           [0017]      FIG. 3  is side view of an insulation containment member of the adjustable insulation containment apparatus. 
           [0018]      FIG. 4  is a fragmentary and enlarged side view of two insulation containment members being joined together to form the adjustable insulation containment apparatus. 
           [0019]      FIG. 5  is a fragmentary view of the adjustable insulation containment apparatus being filled with insulation. 
           [0020]      FIG. 6  is a perspective view on a reduced scale of an insulation containment member in a folded state. 
           [0021]      FIG. 7  is a modified embodiment of the adjustable insulation containment apparatus in accordance with the present invention shown positioned over a ventilation duct in an attic structure. 
           [0022]      FIG. 8  is an enlarged and fragmentary view of the modified containment apparatus showing a wall joined to a rafter. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0023]    As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. 
         [0024]    The reference numeral  1  generally represents an adjustable insulation containment apparatus in accordance with the present invention, which is shown in  FIGS. 1 and 5  in a building attic  2  and covering a circular heating and air conditioning ventilation duct  3 . 
         [0025]    The attic  2  includes a series of spaced and parallel wooden beams or ceiling joists  10  to which is attached a ceiling  11  of an upper floor of a structure supporting the attic  2 . The joists  10  have top surfaces  12  supporting the ventilation duct  3 . The ceiling  11  includes a layer of sheet rock  11 . As is shown in  FIG. 5 , an insulation blanket  15  is installed in the attic  2 . The insulation blanket  15  is positioned on top of the sheet rock  13  and the joists  10  so that the insulation  15 , when completely installed, forms a generally uniform layer of insulation across the entire ceiling  11 . Preferably, the insulation blanket has an overall depth of at least 12 inches relative to the top of the sheet rock  13  and may be constructed of blown cellulose, fiberglass, or the like when fully installed. 
         [0026]    The heating and air conditioning duct  3  is a conventional type of ductwork utilized in houses and other types of building construction. The duct  3  is constructed of conventional 6-inch diameter aluminum tubing and is shown as an elongate relatively straight horizontal duct run  18 . The duct run  18  is shown extending generally perpendicular to the joist  10  and rests on the top of the joist  10  so as to extend thereabove. It is noted that in accordance with the present invention, the containment apparatus  1  can be modified for different types of duct, for example square or rectangular duct. The containment apparatus  1  can also be modified in accordance with the present invention to accommodate ducts having various widths and heights as will be discussed with respect to the embodiments discussed below. 
         [0027]    The insulation containment apparatus  1  includes multiple elongate containment members  20  that may be folded to form an end panel  21  and opposing side panels  22  and  23 . The insulation containment apparatus  1  is assembled by joining two or more containment members  20  together as shown in  FIGS. 1 and 5 , to receive and retain the insulation as it is installed. 
         [0028]    Prior to use, the containment members  20  are elongate and planar as shown in  FIG. 3 . Preferably the containment members  20  are constructed so as to provide a desired height of insulation above a particular duct  3 . The containment members  20  shown in  FIG. 1  are approximately 14 inches tall to retain about 12 inches of insulation  15  above the joists  10 , thereby insulating the duct run  18 . It is foreseen that other sizes of containment members  20  could be utilized depending upon the desired insulation level or duct size. The containment members  20  are illustrated to be about 6 feet long, with each end panel  21  and side panel  22  and  23  being about 2 feet long. The 2-foot width of end panel  21  provides room for enough insulation to adequately insulate the duct  3 . 
         [0029]    The end panel  21  and opposing side panels  22  and  23  are formed when a containment member  20  is folded along lines of weakness or score lines  27  and  28  that extend upward from notches  30  and  31  formed when selectively removable strips  32  and  33  are detached from their respective side panels  22  and  23 . In production, the score lines may be perforations in the cardboard material from which the containment member  20  is made. The primary purpose of the notches  30  and  31  is to facilitate mating of one containment member  20  with another containment member  20  as the insulation containment apparatus  1  is assembled over a duct run  18 . 
         [0030]    Each end of containment member  20  is formed with a hook  34  that defines a channel  36  for receiving a corresponding notch  30  or  31  in a second containment member  20 , as illustrated in  FIG. 4 . Thus, once the containment member  20  is folded, it can be removably secured, or ganged, to another containment member  20  by mating the hook  34  of the other containment member  20  into the notches  30  and  31  of the first containment. In continuing fashion, a multiplicity of insulation containment members  20  may be assembled to form the adjustable insulation containment apparatus  1 . The number of containment members  20  required for a particular containment apparatus  1  will depend on the length of the duct run  18 . 
         [0031]    The containment members  20 , when in use for containing insulation  39  rest upon the joist tops  12  in the attic  2 . Each containment member  20  has an arch-shaped opening  35  sized so as to fit over the duct  3  as the insulation containment members  20  are assembled over the duct run  18 . Once the required number of insulation containment members  20  are placed over the duct run  18 , the insulation containment apparatus  1  is assembled. As is shown in  FIG. 5 , the insulation containment apparatus  1  comprises various compartments  38  that are formed as the containment members  20  are joined. The compartments  38  of the apparatus  1  are filled with insulation  39 , such as by blowing the insulation  39  from a tube  42  attached to a conventional insulation blowing apparatus (not shown). 
         [0032]    In the preferred embodiment, the containment members  20  are highly flexible and constructed of a relatively thick cardboard. The cardboard is corrugated to facilitate folding along score lines  27  and  28 . While the illustrated embodiment utilizes cardboard for constructing the containment members  20 , it is foreseen that other materials of construction such as plastic could be utilized for this purpose. 
         [0033]    Generally, the containment members  20  should be lightweight and relatively long-lived in an attic environment. When the containment members  20  are constructed of cardboard or other flammable material, they may be treated with a fire retardant to reduce the likelihood of combustion. 
         [0034]    Shown in  FIG. 6  is the containment member  20  in a folded state. For transport and storage, the containment members  20  may be laid flat, or folded for ease of transport or storage. The containment member  20  may be bent or folded at the vertical score lines  27  that define the end panel  21  and the side panels  22  and  23 , with the side panels  22  and  23  then being folded inwardly, as is shown in  FIG. 6 . In the folded state, the containment member  20  takes up relatively little space and can be easily moved about by an installer. 
         [0035]    Illustrated in  FIG. 2 , the insulation containment apparatus  1  is adjustable to accommodate different sizes and shapes, such as a rectangular ventilation duct  45 . In practice, it is common for rectangular ventilation ducts  45  to be about 10 inches high and 18 or 24 inches wide. The containment member  20  has removable strips  48  and  49  form notches  50  and  51  when removed. The containment member  20  is folded at notches  50  and  51 , thereby increasing the width of end panel  21  to allow receipt of the rectangular ventilation duct  45 . The primary purpose of the notches  50  and  51  is to facilitate mating of one containment member  20  with another containment member  20  as the insulation containment apparatus  1  is assembled over a duct run  18 . 
         [0036]    To accommodate the depth and increased width of the ventilation duct  45 , each containment member  20  has detachable tabs  54  and  55 . The end panel  21  is lightly scored to allow relatively easy detachment of tabs  54  and  55  to allow the containment member  20  to fit over the ventilation duct  45 . 
         [0037]    Because the containment member  20  is scored along lines  27  and  28 , it is easily folded therealong and it may be desirable to reinforce the end panel  21  so it does not fold along lines  27  and  28  when rectangular ventilation ducts  45  is being insulated. Accordingly, the detachable tabs  54  and  55  may be attached, as by stapling, at the top of the end panel  21  at score lines  27  and  28 , as illustrated in  FIG. 2 . When so attached, the detachable tabs  54  and  55  reinforce end panel  21  along score lines  27  and  28 , thereby increasing its structural integrity. 
         [0038]    The containment members  20  are constructed to accommodate rectangular ventilation ducts that are wider than illustrated in  FIG. 2 . Each containment member  20  has secondary detachable tabs  58  and  59  for this purpose. When such secondary detachable tabs  58  and  59  are removed, a wider ventilation duct (not shown) can be accommodated and insulated by the insulation containment apparatus  1 . 
         [0039]    The containment member  20  has removable strips  61  and  62 , which form notches when removed. The containment member  20  is folded at the notches formed by removing strips  61  and  62 , thereby increasing the width of end panel  21  to allow receipt of the wider (such as 24-inch) rectangular ventilation duct. The primary purpose of the notches formed by detaching strips  61  and  62  is to facilitate mating of one containment member  20  with another containment member  20  as the insulation containment apparatus  1  is assembled over a duct run. 
         [0040]    Illustrated in  FIG. 7  is a second embodiment of an adjustable insulation containment apparatus according to the present invention generally represented by the reference numeral  70 . The apparatus  70  is in many respects similar to the apparatus  1  and description of common features will not be repeated in detail herein. The apparatus  70  includes a pair of elongate side panels  72  and  73  that are formed by unfolding a scored and folded sheet and that in use are spaced by spacer end panels  74 , placed at either end of the apparatus  70 . In this manner the side panes  72  and  73  have a plurality of vertical scores  75  equally spaced therealong. Additional spacer panels  74  may be placed along the spacer panels  74 . The spacer panels  74  are attached at opposite sides thereof to the side panels  72  and  73  and extend from an intermediate vertical location along the side panels  72  and  73  to the tops of the side panels  72  and  73 . 
         [0041]    The apparatus  70  is shown in an attic structure  76  positioned on a series of equally spaced ceiling joists  77 . Running between the side panels  72  and  73  and beneath the spacer panels  74  is a ventilation duct  79 . The apparatus  70  forms one or more compartments  80  about the duct  79  to hold insulation (not shown), as is illustrated with respect to the apparatus  1 . In the embodiment illustrated in  FIG. 7 , the side panels  72  and  73  are relatively flexible and constructed of a relatively thick foam board, preferably of approximately three eights of an inch in thickness. 
         [0042]    The apparatus  70  may include alternative spacing means, such as spacing member  82  and spacing wire  83 . The elongate spacing member  82  is formed with slots  85  for receiving the tops of opposing side panels  72  and  73 . The slots  85  are spaced so as to hold the side panels  72  and  73  apart at a distance approximating the width of spacer panels  74 . In the embodiment illustrated in  FIG. 7 , the spacing member  82  is constructed of a relatively thick foam board. 
         [0043]    Also shown in  FIG. 7  is the spacing wire  83 , which also serves to maintain spacing of side panels  72  and  73 . The side panels  72  and  73  have opposing receiving holes through which the spacing wire  83  runs. The spacing wire  83  runs through a keeper  87  that is placed on the wire  83  in the space between the side panels  72  and  73 . The keeper  87  allows the spacing between the side panels  72  and  73  to be adjusted to the desired distance. 
         [0044]    Because of the need for adjustability and configuration of certain attics or because it is desirable to secure the apparatus  70  in a fixed location for certain reasons, the side panels  72  and  73  may be formed near the base thereof with a notch  89 , which allows the side panels  72  and  73  to be secured to floor joists  77 . When in use, as illustrated in  FIG. 8 , the side panels  72  and  73  are stapled at the base  90  to one or more of the floor joists  77 . In use, the apparatus  70  is filled with insulation to the top thereof to insulate the duct  79  as has been described for the previous embodiment. 
         [0045]    It is to be understood that while certain forms of the present invention have been illustrated and described herein, it is not to be limited to the specific forms or arrangement of parts described and shown.