Insulation system and spacer for an insulation system

Abstract

An insulation system mounting to a substrate includes an insulation layer such as spray foam insulation, loose insulation, blown in insulation, batting or other insulations. Spacer elements mount to the substrate in a spaced apart arrangement and receive attachment elements on mounting surfaces of the spacer elements. An outer layer mounts to the attachment elements and forms a gap to the insulation layer. Each spacer has a base portion, legs extending from a face of the base portion, and a planar mounting surface at an extended end of the legs. Flanges extend from the legs or the cross-portion substantially parallel or obliquely to a face of the base portion. Each has interlocking surfaces engaging and meshing with the insulation to retain the insulation layer against the substrate, with the mounting surface spaced beyond the insulation layer.

Description

[0001] INSULATION SYSTEM AND SPACER FOR AN INSULATION SYSTEM

[0002] Cross-Reference To Related Application

[0003] This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 557,347, filed February 23, 2024, the disclosure of which is incorporated herein by reference in its entirety.

[0004] Background of the Invention

[0005] Field of the Invention

[0006] The present invention is directed to an insulation system and in particular to a continuous insulation system, and to a spacer for the insulation system. Description of the Prior Art

[0007] Conventional insulation systems for building are typically on an interior face of the wall or within the wall between studs. Fiberglass insulation in rolls is placed between studs. Insulation may also be blown into spaces within the walls. Another common configuration uses foam or other panels mounted on the interior surface. Such construction systems are well known and utilized widely with the system used depending on climate, cost, and materials.

[0008] Insulation systems typically lack continuous unbroken air, vapor, thermal and water control layers in the same plane. Many insulation systems have a broken thermal layer between each framing member. Moreover, such systems require a water control layer and / or a vapor control layer, but such layers have breaks or gaps and lack continuity. In addition to unwanted heat transfer, the configuration of such systems may lead to water damage or mold issues. Much of the structure is outside of the insulation layer and this mass not available to trap heat within the insulated space in cold climates and to maintain a cooler interior in warm climates. Such systems therefore lose efficiency and raise heating and / or cooling costs. To meet building codes and achieve sufficient R-value framing may require larger more expensive studs to accommodate thicker insulation. However, such thicker interior insulation systems decrease the area of the interior rooms. With conventional systems, rewiring and plumbing may be intrusive and complicated so that any repairs or updates are messy, time consuming and expensive.

[0009] It can be seen that a continuous insulation system is needed that addresses the deficiencies of conventional insulation systems. Such a system should be suitable for mounting to either an interior or exterior surface and able to insulate over the mass of the structural wall. Such a system should provide continuous insulation without breaks for air, vapor, and water control and to prevent thermal bridging through the wall. The insulation should be mountable to a wide variety of structures and surfaces including metal shipping containers. Such a system should be inexpensive, easy to install and achieve improved efficiency. The present invention addresses these problems, as well as others associated with insulation systems.

[0010] Summary of the Invention

[0011] The present invention is directed to an insulation system, generally configured for mounting to a building structure and more particularly, to an outer wall of a building structure. Although the insulation system is suited for application to an exterior surface of a wall, the insulation system is adapted for use with many types of applications for new construction, as well as part of remodeling projects and may be retrofit into existing structures. The present invention may be able to bring old construction up to code. The insulation system improves insulating performance when installed on the exterior with increased mass of the structure within the heated or cooled portion on the inside of the insulation system. However, the insulation system may be installed on the surfaces of interior sides of walls, or directly on framing. The insulation system may be adapted over studs of conventional framing, to concrete block or other masonry construction, to log or timber structures, or many other building systems. Moreover, in some applications, the insulation system may be fixed to floors, ceilings, to an inner surface below a roof, under new roof sheathing, and even over existing roof shingles. As explained hereinafter, in some embodiments the insulation system may be adapted for attachment to metal structures such as pole buildings or intermodal shipping containers.

[0012] The insulation system generally includes an insulation layer applied against the wall. The insulation layer may be spray in place foam insulation having a high R-value. Spacer assemblies are distributed in a spaced apart pattern on the wall. Attachment elements, such as furring strips, may extend vertically or horizontally and attach over the spacer assemblies. Other attachment elements may have different configurations. The mounting strips, or other attachment elements, mount to an outer mounting surface of the spacer assemblies. Cables, tubing, wiring or other lines may be routed against the wall before being covered by the insulation system and may be buried in insulation or routed through the spaces formed by the gaps. Utility boxes and other devices can be fastened to furring strips or installed prior to application of spray foam insulation. Alternatively, spaces for receiving electrical boxes and other common wall-mounted devices can be cut into the insulation and outer layer using a standard drywall keyhole saw or other conventional techniques. The spacer assemblies are formed one or more spacers. If multiple spacers are used in a spacer assembly, the spacers are positioned in an abutting side by side arrangement. The spacers are aligned so a face of an upper mounting portion of each spacer receives one of the furring strips or other attachment elements. In one embodiment, each spacer includes a base portion with a center leg extending upward from the base between opposed angled end legs. An intermediate tier portion extends intermediate and parallel to the base portion and the upper mounting portion. The intermediate tier is a planar element substantially parallel to the base portion and spaced apart from the base portion a distance approximately equal to a desired thickness of the insulation layer. The tier portion may serve as a guide when applying spray foam insulation and also serve as a retainer for the outer surface of the insulation. A planar transverse bracing portion extends between and supports the legs, the base portion, and the intermediate tier portion. A support gusset extends outward from the end legs and provides further bracing to the base portion. The base portion includes perforations extending therethrough into which foam insulation extends to help interlock the insulation to the spacers which function as anchors. Edges of the base portion include double tongue and groove slots to receive and further interlock the insulation to the spacers. Mounting holes formed through the base portion receive fasteners to attach the spacer to a structural surface. A flashing edge portion forms a flange that extends from an end of the intermediate tier and provides surfaces to engage and retain the sprayed foam insulation and for some applications to provide water protection. Flanges extend from and are spaced along the legs and provide additional engagement and water protection. Wiring clips provide for routing wiring, utilities, and other lines along the spacers.

[0013] It is appreciated that the structural elements for mounting siding include the wall, which may be a structural load bearing wall. The spacer assemblies are attached against the wall or other structure surface. Furring strips attach to the spacers’ mounting portions, which are exposed. An outer layer, typically siding such as cladding, stucco, brick, veneers, or other outer layers, depending upon the application and requirements, is attached to the furring strips or mounting elements. A gap may be formed between the insulation and the outer layer. The gap may improve insulation performance and also aid controlling and removing moisture to prevent mold, mildew, and other damage from water. These elements achieve a rigid framework and exterior protection that provides strong bracing and support for the outer layer.

[0014] According to one aspect of the present invention, for mounting to a ferromagnetic surface, the spacer may be modified to include a recess in an underside of the base portion to receive a magnet, such a powerful rare earth magnet. The magnet may be combined with adhesive to attach the spacers. The magnet should be sufficiently strong to retain the spacers in place while adhesive applied to an underside of the base portion sets.

[0015] Each spacer is configured to provide ridges, flanges, tongues, grooves, orifices, recesses, and / or other surface features to allow the sprayed foam insulation to flow onto and into these surface features so the spacers and the foam insulation form an interlocking engagement, and the foam insulation is properly anchored to the wall and supported. It is further appreciated that the mounting surface is spaced beyond the thickness of the foam insulation layer and provides exposed mounting surfaces for furring strips. The intermediate tier provides a general guide for the thickness of the spray foam insulation layer. The tier portion also provides retention against foam insulation beneath it and the end flange may extend into the foam insulation. Moreover, the spray foam insulation forms a continuous insulation layer across the wall. Although a vapor barrier may also be added to the system, with the continuous insulating layer made of a water impervious material, for some applications the need for a separate vapor barrier may be eliminated.

[0016] The spacers may be molded plastic or are preferably made of materials that have a low thermal transfer rate and prevent thermal bridging across the insulation layer. The spacer elements are also lightweight and impervious to water for durable and inexpensive construction. It can be appreciated that the insulation system of the present invention reduces the likelihood for water damage, mold, and other problems that conventional building techniques are prone to, especially when set in a damp environment. The insulation layer may include openings or capillary channels that are configured to keep moisture away from other layers that may be damaged by moisture. The spacer assemblies may be a single spacer or may be formed of several spacers positioned side by side to form an enlarged mounting portion. Moreover, the distance between spacer assemblies or individual spacers may be varied depending upon the application. Spacer assemblies may be positioned in a rectangular grid with spacer assemblies aligned in vertical columns and horizontal rows, but other mounting patterns may be utilized to meet the particular requirements of the installation. The spacers are sized to be sufficiently tall so that the mounting portion protrudes beyond the thickness of the insulation layer and provides an exposed surface for attaching mounting elements, such as furring strips, as is required for the particular type of construction.

[0017] According to one aspect of the present invention, a water collection system may be incorporated into the insulation system. The water collection system is placed below a window frame or other structures that may interrupt a planar wall. The water collection and removal system is configured for use with the insulation system. The water collection and removal system made of one or more collector units. The collector units are modular and may connected in series below the window frame to form an extended water collection band. Each collection unit includes a front wall, a rear wall, opposed end walls, and a bottom. The walls form a collection space to collect water. The bottom is sloped downward toward a bottom nozzle. A drainage tube or weeping cord attaches to the lower nozzle. An end tab extends from one end of each collection unit and engages an end wall of an adjacent collector unit to form a continuous collection zone below the window. To ensure there are no gaps between the collection units, tape or another water impervious element may be placed to bridge over the end walls of adjacent collection units to form a continuous uninterrupted upper water collection face.

[0018] The collection system installs against the wall below the window frame or other structure. The collection system has a modular configuration with a width that is varied by simply adding or removing collector units. Water collected in the space formed by the collector unit walls flows along the sloped bottom to the nozzle extending downward from the lowest collection point in the collector unit. Water is then able to flow through tubing / weeping cord away from the wall and insulation system. The collector system is mounted to the wall or other structure subsurface and then can be covered by the insulation layer. The tubing or weeping cord is covered by the insulation layer but provides a path to remove water and prevent moisture damage.

[0019] According to one aspect of the present invention, an insulation system mounts to a substrate, and includes: an insulation layer; a plurality of spacer elements mounted to the substrate in a spaced apart arrangement, each of the spacer elements comprising interlocking surfaces and a mounting surface spaced apart from interlocking surfaces; the insulation layer engaging and meshing with the interlocking surfaces of the spacer elements to retain the insulation layer against the substrate, the mounting surface being spaced beyond the insulation layer; attachment elements mounting to the mounting surfaces of the spacer elements; an outer layer mounted to the attachment elements, the outer layer and the insulation layer forming a gap.

[0020] According to one aspect, the insulation layer is spray foam insulation. The insulation spacer may include a plurality of surface portions configured to interlock with the spray foam insulation. The spacer element may include: a base portion; one or more legs extending from a face of the base portion; a cross-portion at an extended end of the one or more legs; a plurality of flanges extending from at least one of the one or more legs or the crossportion substantially parallel or obliquely to a face of the base portion.

[0021] The spacer element may include an intermediate planar portion substantially parallel and spaced apart from the base portion and the cross-portion and intermediate the crossportion and the base portion.

[0022] According to one aspect of the present invention, an insulation spacer includes: a base portion; one or more legs extending from a face of the base portion; a cross-portion at an extended end of the one or more legs; a plurality of flanges extending from at least one of the one or more legs or the crossportion substantially parallel or obliquely to a face of the base portion.

[0023] The insulation spacer may include an intermediate planar portion substantially parallel and spaced apart from the base portion and the cross-portion and intermediate the crossportion and the base portion.

[0024] These features of novelty and various other advantages that characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and the objects obtained by its use, reference should be made to the drawings that form a further part hereof, and to the accompanying descriptive matter, in which there is illustrated and described a preferred embodiment of the invention.

[0025] Brief Description of the Drawings

[0026] Figure l is a perspective view of an exterior of a building having a first embodiment of a wall and an insulation system according to the principles of the present invention with vertically extending furring strips;

[0027] Figure 2 is an exploded perspective view of a wall and insulation system shown in Figure 1;

[0028] Figure 3 is a perspective view of the wall and insulation system shown in Figure 1 partially assembled without an outer layer;

[0029] Figure 4 is a perspective view of the wall and insulation system shown in Figure 1 partially assembled without furring strips or an outer layer;

[0030] Figure 5 is a perspective view of the wall shown in Figure 1 with foam spacers mounted in a spaced apart arrangement and with vertical and horizontal wiring, and without foam insulation, furring strips, or an outer layer;

[0031] Figure 6 is a side sectional view of a wall and the insulation system of the building shown in Figure 1;

[0032] Figure 7 is an exploded perspective view of the wall shown in Figure 2 with foam spacers, a furring strip, and an outer layer;

[0033] Figure 8 is an exploded side view of the wall shown in Figure 7 with foam spacers, a furring strip, and an outer layer;

[0034] Figure 9 is a side sectional view of a foam spacer and the wall and insulation assembly shown in Figure 2;

[0035] Figure 10 is a perspective view of an exterior of a building having a second embodiment of a wall and an insulation system according to the principles of the present invention with horizontally extending furring strips;

[0036] Figure 11 is a perspective view of the wall and insulation system shown in Figure 10 partially assembled without an outer layer;

[0037] Figure 12 is an exploded perspective view of the wall shown in Figure 11 partially assembled with foam insulation, foam spacers, and furring strips, and without an outer layer;

[0038] Figure 13 is an exploded side view of the wall and the insulation system shown in Figure 12;

[0039] Figure 14 is an exploded perspective view of the wall and insulation system shown in Figure 10 without foam insulation;

[0040] Figure 15 is an exploded side view of the wall and the insulation system shown in Figure 14;

[0041] Figure 16 is a perspective view of the wall shown in Figure 10 with foam spacers mounted in a spaced apart arrangement and with vertical and horizontal wiring, and without foam insulation or an outer layer;

[0042] Figure 17 is a perspective view of the wall shown in Figure 10 with foam spacers mounted in a spaced apart arrangement and with vertical and horizontal wiring, and without foam insulation, furring strips, or an outer layer; (same as Figure 5)

[0043] Figure 18 is a side sectional view of the wall and the insulation system of the building shown in Figure 10;

[0044] Figure 19 is a side sectional view of a foam spacer and the wall and insulation assembly shown in Figure 18;

[0045] Figure 20 is perspective view of a first embodiment of an insulation spacer bracket for the insulation system shown in Figure 19;

[0046] Figure 21 is a front elevational view of the insulation spacer bracket shown in Figure 20;

[0047] Figure 22 is a side elevational view of the insulation spacer bracket shown in Figure 20;

[0048] Figure 23 is a top plan view of the insulation spacer bracket shown in Figure 20;

[0049] Figure 24 is a bottom plan view of the insulation spacer bracket shown in Figure 20;

[0050] Figure 25 is a bottom perspective view of the 10 is a sectional view of the insulation spacer bracket shown in Figure 20 configured with a magnet mounting recess;

[0051] Figure 26 is a perspective view of insulation spacer brackets and wiring retained by the brackets for the insulation systems shown in Figures 5 and 17;

[0052] Figure 27 is a perspective view of an insulation spacer bracket and wiring retained by the brackets for the insulation systems shown in Figure 26;

[0053] Figure 28 is a perspective view of a window with a system for conducting water from below a window for the insulation system shown in Figure 1;

[0054] Figure 29 is a sectional view of a window with a system for conducting water from below a window taken along line 29-29 of Figure 28;

[0055] Figure 30 is a sectional detail view of the system for conducting water from below a window of Figure 29;

[0056] Figure 31 is a perspective view of a collection element for the system for conducting water from below a window of Figure 28;

[0057] Figure 32 is a front elevational view of the collection element shown in Figure 31;

[0058] Figure 33 is a side elevational view of the collection element shown in Figure 31;

[0059] Figure 34 is a top plan view of the collection element shown in Figure 31;

[0060] Figure 35 is a bottom plan view of the collection element shown in Figure 31;

[0061] Figure 36 is perspective view of an alternate embodiment of an insulation spacer bracket for the insulation system of the present invention;

[0062] Figure 37 is a front elevational view of the insulation spacer bracket shown in Figure 36;

[0063] Figure 38 is a side elevational view of the insulation spacer bracket shown in Figure

[0064] 36;

[0065] Figure 39 is a top plan view of the insulation spacer bracket shown in Figure 36;

[0066] Figure 40 is a bottom plan view of the insulation spacer bracket shown in Figure 36;

[0067] Figure 41 is perspective view of a second alternate embodiment of an insulation spacer bracket for the insulation system of the present invention;

[0068] Figure 42 is a front elevational view of the insulation spacer bracket shown in Figure 41;

[0069] Figure 43 is a side elevational view of the insulation spacer bracket shown in Figure 41;

[0070] Figure 44 is a top plan view of the insulation spacer bracket shown in Figure 41;

[0071] Figure 45 is a bottom plan view of the insulation spacer bracket shown in Figure 41;

[0072] Figure 46 is perspective view of a third alternate embodiment of an insulation spacer bracket for the insulation system of the present invention;

[0073] Figure 47 is a front elevational view of the insulation spacer bracket shown in Figure 46;

[0074] Figure 48 is a side elevational view of the insulation spacer bracket shown in Figure 46;

[0075] Figure 49 is a top plan view of the insulation spacer bracket shown in Figure 46;

[0076] Figure 50 is a bottom plan view of the insulation spacer bracket shown in Figure 46;

[0077] Figure 51 is perspective view of a fourth alternate embodiment of an insulation spacer bracket for the insulation system of the present invention;

[0078] Figure 52 is a front elevational view of the insulation spacer bracket shown in Figure 51;

[0079] Figure 53 is a side elevational view of the insulation spacer bracket shown in Figure 51;

[0080] Figure 54 is a top plan view of the insulation spacer bracket shown in Figure 51;

[0081] Figure 55 is a bottom plan view of the insulation spacer bracket shown in Figure 46;

[0082] Figure 56 is perspective view of a fifth alternate embodiment of an insulation spacer bracket for the insulation system of the present invention;

[0083] Figure 57 is a front elevational view of the insulation spacer bracket shown in Figure 55;

[0084] Figure 58 is a side elevational view of the insulation spacer bracket shown in Figure 55;

[0085] Figure 59 is a top plan view of the insulation spacer bracket shown in Figure 55; and

[0086] Figure 60 is a bottom plan view of the insulation spacer bracket shown in Figure 55.

[0087] Detailed Description of the Preferred Embodiment

[0088] Referring now to the drawings and in particular to Figure 1, an insulation system, generally designated 100 is shown mounted to a substrate, such as an outer wall 1002 of a building structure 1000. Although shown applied as an exterior surface of a wall 1002, the insulation system 100 is suited for many types of applications on any structure, and may be used for new construction, as well as part of remodeling projects and may be retrofit into existing structures. The insulation system 100 may be mounted to diverse types of surfaces and is not exclusive to outer walls. The insulation system 100 improves insulating performance when installed on the exterior with increased mass of the structure 1000 within the heated or cooled portion on the inside of the insulation system 100. However, the insulation system 100 may be installed on the surfaces of interior sides of walls, or directly on framing. Moreover, the insulation system 100 may be adapted over studs of conventional framing, to concrete block or other masonry construction, to log or timber structures, or many other building structural systems. Moreover, in some applications, the insulation system 100 may be fixed to floors, ceilings and / or to an inner surface below a roof. As explained hereinafter, in some embodiments the insulation system 100 may be adapted for attachment to metal structures such as pole buildings or intermodal shipping containers.

[0089] Referring to Figures 2-6, the insulation system 100 generally includes an insulation layer 102 applied against the wall or other structure surface 1002. The insulation layer 102 may be spray in place foam insulation having a high R-value. Spacer assemblies 112 are distributed in a spaced apart pattern on the wall 1002. Attachment elements for attaching outer siding, such as furring strips 106, may extend vertically in parallel, as shown in Figures 1-3 and 6-9. However, in an alternate mounting configuration shown in Figures 10-16 and 18-19, furring strips 108 extend horizontally in parallel. Other types of attachment elements may have different configurations. The mounting strips 106 or 108, or other attachment elements, mount to an outer surface of the spacer assemblies 112. As shown in Figures 26-27, cables, tubing, wiring or other lines 110 may be routed against the wall 1002 before being covered by the insulation system 100. Spaces for receiving electrical boxes and other common wall-mounted devices can be cut into the insulation 102 and outer layer 104 using a standard dry wall keyhole saw or other conventional techniques and then sealed. For some of these wall mounted devices, a water collection system may be installed under the insulation layer 102 to help dissipate moisture, as described below.

[0090] The spacer assemblies 112 are formed of one or more spacers 120. A first embodiment is shown in Figures 20-24. If multiple spacers 120 are used in a spacer assembly 112, the spacers 120 are positioned in an abutting side by side arrangement. The spacers 120 are aligned so a planar face of an upper mounting portion 150 of each spacer receives one of the furring strips 106 or 108. For some embodiments, the upper mounting portion 150 may be capped with a sheet metal element with a flange that may be bent around the underside of the upper mounting portion 150 to be held in place or a sheet metal element may be molded into the spacer 120. The metal portion may achieve a non-combustible rating the construction. Each spacer 120 includes a base portion 122. A center leg 124 extends upward from the base between opposed angled end legs 126. Capillary breaks 142 prevent water penetration along the legs 124 and 126. An intermediate tier portion 130 extends intermediate and parallel to the base portion 122 and the upper mounting portion 150. The intermediate tier portion 130 is a planar element substantially parallel to the base portion 122 and spaced apart from the base portion 122 a distance approximately equal to a desired thickness of the insulation layer. The planar tier 130 may serve as a guide when applying spray foam insulation and also serve as a retainer for the outer surface of the insulation. A planar transverse bracing portion 128 extends between and supports the legs 124 and 126, the base portion 122 and the intermediate tier portion 130. In the embodiment of Figures 20-24, the bracing portion is a planar structure, and forms opens extending through the spacer 120. A support gusset 138 extends outward from the end legs 126 and provides further bracing to the base portion 122. The base portion 122 includes perforations extending therethrough into which foam insulation extends to help interlock the insulation to the spacers 120 which function as anchors. Edges of the base portion include double tongue and groove slots 136 to receive and further interlock the insulation to the spacers 120. Furthermore, the slots 136 provide for interlocking with adhesives, such as may be used for some applications. Mounting holes 140 through the base portion receive fasteners to attach the spacer 120 to a surface. A flashing edge portion forms a flange 146 that extends from an end of the intermediate tier and provides surfaces to engage and retain the sprayed foam insulation 102 and for some applications to provide water protection. Flanges 148 extend from and are spaced along the legs 124 and 126 and provide additional engagement and water protection. The flanges 148 form a shallow point and extend outward and downward toward the base portion 122. The legs 126 taper slightly from the base portion 122 to the mounting portion 150. Wiring clips 132 provide for routing wiring, utilities, and other lines 110 along the spacer assemblies 112. A typical routing of wiring 110 is shown in Figures 26-27. Moreover, the wiring clips 132 may be mounted in other positions for other applications and routing requirements.

[0091] Referring now to Figures 36-60, alternate embodiments of spacers 120A, 120B, 120C, 120D and 120E are shown. The spacers 120A, 120B, 120C, 120D and 120E are similarly configured but have different dimensions, and more particularly have different heights as may be needed for different applications requiring insulation layers of different thicknesses. In exemplary embodiments the spacer 120A has a height of 9.5 inches, the spacer 120B has a height of 7.5 inches, the spacer 120C has a height of 5.5 inches, the spacer 120D has a height of 3.75 inches, and the spacer 120E has a height of 2.5 inches. It is appreciated that the dimensions of the spacers may be varied to fulfill the requirements of the particular application. The spacers 120A, 120B, 120C, 120D and 120E are generally similar to the spacer 120 in the general configuration and include a base portion with perforations, angled legs and a center leg, and an intermediate tier or flange that is generally parallel to the base.

[0092] The spacers 120 A, 120B, 120C, 120D and 120E are aligned so a planar face of an upper mounting portion 170 of each spacer receives one of the furring strips 106 or 108. The upper mounting portion 170 may be round or oval and extends outward beyond opposed faces of the other structures of the spacers 120 A, 120B, 120C, 120D and 120E, as shown in Figures 39, 40, 44, 45, 49, 50, 54. 55. 59 and 60. The enlarge mounting portionl70 provides a larger surface in which to insert mounting elements such as screws or nails. The widened portion is easier for installers to see and may have a diameter / width of 3.5 inches, so that it can be seen if a standard 2x4 stud is attached. In addition, the spacers 120A, 120B, 120C, 120D and 120E include brace portions 172 extending between the legs and center leg. The brace portions 172 may include a section 174 of decreased thickness to minimize the mass of the spacers 120A, 120B, 120C, 120D and 120E and decrease thermal bridging. Moreover, certain types of insulation may adhere better without gaps in certain applications if the brace portions 172 are free of gaps. Clips 176 extend obliquely from opposite positions on the spacers 120A, 120B, 120C, 120D and 120E. The positioning of the clips allows for greater flexibility and allows easier routing of wires and other conduits either vertically or horizontally. As shown in Figures 41-44, the spacers 120B include loops 178 for retaining and routing tubing, wiring etc. Moreover, the loops 178 may be used with zip ties to retain larger diameter wiring, cables, tubing etc. It is appreciated that spacers 120, 120A, 120C, 120D and 120E may also include similar loops 178. As shown in Figures 7-9 and 14-15, the structural elements for mounting siding 104 include the wall or other structure surface 1002, which may be a structural load bearing wall. The spacer assemblies 112 are attached against the wall 1002 or other substrate. Furring strips 106 or 108 attach to the mounting portions 150, which are exposed. An outer layer 104, typically siding such as cladding, stucco, brick, veneers, or other outer layers, depending upon the application and requirements, is attached to the furring strips 106 or 108 or to other mounting elements. A gap 114 may be formed between the insulation 102 and the outer layer 104. It has been found that a gap 114 of at least 0.75 inches achieves satisfactory airflow to promote drying should any moisture breach the exterior cladding 104. The gap 114 also promotes drying of furring strips 106 or 108 so they dry faster if water breaches the exterior layer 104. The gap 114 may create an unobstructed path for air to enter at a bottom of the insulation system 102 and flow upward to a vent, such as is placed on a roof. The gap 114 may improve insulation performance and also help to control and remove moisture to prevent mold, mildew, and other damage from water. These elements 1002, 112, 106 or 108, and 104 achieve a rigid framework for and exterior protection that provides bracing and support for the outer layer 104.

[0093] Referring to Figure 25, for mounting to a ferromagnetic surface, the spacer 120 may be modified to include a recess 160 in an underside of the base portion to receive a magnet 162, such a powerful rare earth magnet. The magnet 162 may be combined with adhesive to attach the spacers 120. The magnet 162 should be sufficiently strong to retain the spacers 120 in place while adhesive applied to an underside of the base portion 122 sets. Such magnetic mounting may be required for insulating certain structures such as intermodal shipping containers or pole structures with metal siding where the metal mounting surfaces do not allow for mounting with more conventional hardware. The adhesive, such as an epoxy or polyurethan construction adhesive flows into the slots 136 to provide stronger anchoring of the spacers 120.

[0094] As shown in Figures 3-4, 6, 9, 11, 18 and 19, each spacer 120 is configured to provide ridges, flanges, tongues, grooves, orifices, recesses, and other surface features to allow the sprayed foam insulation 102 to flow into the spacers 120 and the foam insulation properly interlock. When engaged, the foam or other insulation 102 is securely anchored to the wall 1002 and supported. It is further appreciated that the mounting surface 150 is spaced beyond the thickness of the foam insulation layer 102 and provides mounting surfaces for furring strips 106 or 108. The intermediate tier 130 provides a general guide for the thickness of the spray foam insulation layer 102. The tier portion 130 also provides a retention against foam insulation beneath it. The end flange 146 is recessed into the foam insulation to extend upward and forms a flashing that prevents water from entering behind the tier portion 130, such as when installed on a wall or roof. Moreover, the spray foam insulation 102 forms a continuous insulation layer across the wall 1002. Although a vapor barrier may also be added to the system 100, it can be appreciated that with the continuous insulating layer 102 made of a water impervious material, for many applications the need for a separate vapor barrier may be eliminated. It is appreciated that a spray foam insulation layer 102 forms a continuous coating / sheet and eliminates the deficiencies of prior art systems that have gaps or must overlap and may lead to lower insulating efficiencies and / or water and moisture issues.

[0095] In one embodiment, the spacers 120 are molded plastic or made of other materials that have a low thermal transfer rate and prevent thermal bridging across the insulation layer 102. In particular the spacers 120 are made from a plastic material that is 250 times less conductive than steel. The material has a conductivity of 0.18 watts per meter Kelvin compared to 45 watts per meter Kelvin for steel. The spacer elements 120 are also lightweight and impervious to water for durable and inexpensive construction. It can be appreciated that the insulation system 100 of the present invention reduces the likelihood for water damage, mold, and other problems that conventional building techniques are prone to, especially when set in a damp environment. The insulation layer 102 may include openings or capillary channels that are configured to keep moisture away from other layers that may be damaged by moisture. The spacer assemblies 112 may be a single spacer 120 or may be formed of several spacers 120 positioned side by side to form an enlarged mounting portion 150. Moreover, the distance between spacer assemblies 112 or individual spacers 120 may be varied depending upon the application. Although shown mounted in a rectangular grid with spacer assemblies 112 aligned in vertical columns and horizontal rows, other mounting patterns may be utilized to meet the particular requirements of each installation. The spacers 120 are sized to be sufficiently tall so that the mounting portion 150 protrudes beyond the thickness of the insulation layer 102 and provides an exposed surface for attaching the furring strips 106 or 108 or other attachment elements for mounting an exterior protective layer, such as siding, as is required for the particular type of construction.

[0096] Referring now to Figures 28-30, a window 1004 including a pane or panes 1006 and frame 1008 is shown installed on the wall 1002 of the building structure 1000. A water collection system 300 is placed below the window frame 1008 or other structures that may interrupt continuity of the planar wall 1002. The water collection and removal system 300 is configured for use with the insulation system 100. The water collection and removal system 300 system is made of one or more collector units 302. The collector units 302 are modular and may connected in series below the window frame 1008 to form an extended continuous water collection zone. Referring to Figures 31-35, each collection unit 302 includes a front wall 304, a rear wall 306, opposed end walls 308, and a bottom 310. The walls 304, 306 and 308 form a collection zone to collect water. The bottom 310 is sloped downward toward a bottom nozzle 312. A drainage tube or weeping cord 316 attaches to the lower nozzle. An end tab 314 extends from one end of each collection unit 302 and engages an end wall 308 of an adjacent collector unit to form a continuous collection space below the window 1004, as shown in Figure 28. To ensure there are no gaps between ends of the collection units 302, tape or another water impervious element may be placed to bridge over the end walls 308 of adjacent collection units 302 to form a continuous uninterrupted upper water collection face.

[0097] Referring again to Figures 28-30, the collection system 300 installs against the wall 1002 below the window frame 1008 or other structure. The collection system 300 has a modular configuration with a width that is varied by simply adding or removing collector units 302. Water collected in the space formed by the walls 304, 306, 308 flows along the sloped bottom 310 to the nozzle 312 extending downward from the lowest collection point in the collector unit 302. Water is then able to flow through tubing / weeping cord 316 away from the wall 1002 and insulation system 100. The collector system 300 is mounted to the wall or other subsurface and then can be covered by the insulation layer 102. The tubing or weeping cord 316 is also covered by the insulation layer 102, but provides a path to remove water and prevent moisture damage. As shown in Figure 30, a strip of drainage mat 1010 extends up to the bottom of the window 1004 and into the collector unit 302 to ensure water is routed to the collection system 300.

[0098] In a method for mounting insulation 102 and an outer layer 104, such as siding, to a substrate 1000, the spacer elements 120 are mounted to the substrate 1000. The spacer elements 120 are positioned spaced apart from one another and generally aligned vertically and / or horizontally. The spacer elements 120 may be mounted with an adhesive and doublesided tape or other retaining elements may be used to secure the spacer elements 120 so that the elements 120 do not drop downward due to gravity while the adhesive is setting. Furring strips 106 or 108 are attached to the mounting surfaces of the spacers 120. Insulation 102 is applied to the substrate 1000. The insulation system 100 may be used with any form or type of insulation such as but not limited to: loose fill or blown in insulation, batt insulation, adhesively applied spray on insulation, and spray foam insulation. If the insulation 102 is foam insulation, the insulation is sprayed against the substrate 1000 and allowed to interlock with the flanges and surfaces of the spacer elements 120. If the insulation layer 102 is loose or blown insulation, a netting / mesh or a water-resistant layer is attached to the spacers 120 or onto the furring strips 106, 108 and the insulation is introduced / blown into the space between the outer barrier and the substrate 1000 at various spaced apart positions. The water-resistant barrier may be a reflective radiant barrier for improved thermal performance. If the insulation 102 is insulation panels, the panels are mounted to the substrate 1000 with openings formed for the spacer elements 120. If the insulation layer 102 has batting type insulation, the batting is mounted to the substrate 1000 and openings are formed for the spacer elements. The outer layer 104, such as siding is then mounted to the furring strips 106, 108. The insulation 102 should be configured so an outer face of the furring strips 106, 108 extends beyond the outer face of the insulation 102. It is appreciated that a gap may be formed between the outer layer 104 and the insulation 102 to further improve thermal properties such as improved insulation and / or minimizing thermal bridging.

[0099] It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.

Claims

What is claimed is:

1. An insulation system mounting to a substrate, comprising: an insulation layer; a spacer element comprising interlocking surfaces, and a mounting surface spaced apart from interlocking surfaces; the insulation layer engaging and meshing with the interlocking surfaces, the mounting surface being spaced beyond the insulation layer; an attachment element mounting to the mounting surface of the spacer element; an outer layer mounted to the attachment element, the outer layer and the insulation layer forming a gap.

2. The insulation system according to claim 1, wherein the interlocking surfaces comprise flanges.

3. The insulation system according to claim 1, wherein the interlocking surfaces comprise grooves.

4. The insulation system according to claim 1, wherein the interlocking surfaces comprise perforations extending through a portion of the spacer.

5. The insulation system according to claim 1, wherein the insulation layer comprises spray foam insulation.

6. The insulation spacer according to claim 5, comprising a plurality of surface portions configured to interlock with the spray foam insulation.

7. The insulation system according to claim 1, wherein the spacer element comprises: a base portion; one or more legs extending from a face of the base portion; a cross-portion at an extended end of the one or more legs; a plurality of flanges extending from at least one of the one or more legs or the crossportion substantially parallel or obliquely to an upper face of the base portion.

8. The insulation system according to claim 7, the cross-portion comprising a mounting surface substantially parallel to the base portion and extending outward.

9. The insulation system according to claim 8, wherein the mounting surface comprising a round periphery.

10. The insulation system according to claim 7, comprising a planar brace extending between the legs.11 The insulation system according to claim 10, wherein the planar brace comprises a section with an orifice or a section of reduced thickness.

12. The insulation system according to claim 7, wherein the spacer element comprises an intermediate planar portion substantially parallel and spaced apart from the base portion and the cross-portion and intermediate the cross-portion and the base portion.

13. An insulation system mounting to a substrate, comprising: an insulation layer; a plurality of spacer elements mounted to the substrate in a spaced apart arrangement, each of the spacer elements comprising interlocking surfaces and a mounting surface spaced apart from interlocking surfaces; the insulation layer engaging and meshing with the interlocking surfaces of the spacer elements to retain the insulation layer against the substrate, the mounting surface being spaced beyond the insulation layer; attachment elements mounting to the mounting surfaces of the spacer elements; an outer layer mounted to the attachment elements, the outer layer and the insulation layer forming a gap.

14. The insulation system according to claim 13, wherein the insulation layer comprises spray foam insulation.

15. The insulation spacer according to claim 14, comprising a plurality of surface portions configured to interlock with the spray foam insulation.

16. The insulation system according to claim 13, wherein the spacer element comprises: a base portion; one or more legs extending from a face of the base portion; a cross-portion at an extended end of the one or more legs; a plurality of flanges extending from at least one of the one or more legs or the crossportion substantially parallel or obliquely to the face of the base portion.

17. The insulation system according to claim 16, wherein the spacer element comprises an intermediate planar portion substantially parallel and spaced apart from the base portionand the cross-portion and intermediate the cross-portion and the base portion.

18. An insulation spacer, comprising: a base portion; one or more legs extending from a face of the base portion; a cross-portion at an extended end of the one or more legs; a plurality of flanges extending from at least one of the one or more legs or the crossportion substantially parallel or obliquely to an upper face of the base portion.

19. The insulation spacer according to claim 18, comprising an intermediate planar portion substantially parallel and spaced apart from the base portion and the cross-portion and intermediate the cross-portion and the base portion.

20. The insulation spacer according to claim 18, comprising a planar portion extending upward from the base to the cross-portion.

21. The insulation spacer according to claim 18, wherein the one or more legs are planar legs extending in a plane transverse to the planar portion.

22. The insulation spacer according to claim 18, wherein the flanges are spaced apart at a plurality of distances from the base.

23. The insulation spacer according to claim 18, further comprising grooves formed along edges of the base.

24. The insulation spacer according to claim 18, further comprising a plurality of orifices formed through the base.

25. The insulation spacer according to claim 18, comprising a plurality of surface portions configured to interlock with insulation.

26. The insulation spacer according to claim 18, further comprising a clip to retain wiring or other lines against the insulation spacer.

27. The insulation spacer according to claim 18, the cross-portion comprising a mounting surface substantially parallel to the base portion and extending outward.

28. The insulation spacer according to claim 27, wherein the mounting surface comprising a round periphery.

29. The insulation spacer according to claim 27, comprising a planar brace extending between the legs.

30. The insulation system according to claim 29, wherein the planar brace comprises a section with an orifice or a section of reduced thickness.

31. A method of mounting insulation to a substrate comprising: providing a plurality of insulation spacers, each of the spacers comprising: a base portion; one or more legs extending from a face of the base portion; a cross-portion at an extended end of the one or more legs; a plurality of flanges extending from at least one of the one or more legs or the crossportion substantially parallel or obliquely to an upper face of the base portion; mounting the spacers to the substrate in a spaced apart arrangement; attaching furring strips of the spacers; applying a layer of insulation to the substrate; mounting an outer layer to the furring strips.

32. The method according to claim 31, comprising forming a gap between the layer of insulation and the outer layer.

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