Insulation panel system and insulation panel retainer

Abstract

An insulation system mounting to a substrate includes an insulation layer having vacuum insulation panels. Each of the vacuum insulation panels has an inner face, an outer face, and sides extending from the inner face to the outer face. Panel retaining assemblies mount to the substrate in a spaced apart arrangement. Each of the panel retaining assemblies has panel engaging surfaces and a mounting surface spaced apart from the panel engaging surfaces. The mounting surface is spaced beyond the outer face of the vacuum insulation panels. Attachment elements mount to the mounting surfaces of the panel retaining assemblies, and an exterior layer mounts to the attachment elements, with the exterior layer and the insulation layer forming a gap.

Description

[0001] INSULATION PANEL SYSTEM and INSULATION PANEL RETAINER

[0002] Cross-Reference To Related Application

[0003] This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 557,361, 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 panel insulation system and an insulation panel retainer apparatus.

[0007] Description of the Prior Art

[0008] Conventional wall systems for outer walls and other applications 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.

[0009] Prior 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 lost heat, these systems may have water damage or mold issues. Much of the structure is outside of the insulation layer and not available to trap heat within the insulated space. Such systems lose efficiency and raise heating costs. To meet building codes and achieve sufficient R-value framing may require larger more expensive studs. Such interior insulation systems decrease the area of the interior rooms. Rewiring and plumbing may be complicated with conventional systems.

[0010] To achieve higher insulating efficiencies, vacuum insulation panels have been developed. Such panels are typically formed by a rigid vacuum insulation panel with a center core that is evacuated, encased and sealed in a thin, gas-tight envelope. Such panels achieve outstanding thermal resistance with a thin profile. The panels may be placed in a continuous arrangement without gaps to achieve an insulation system with superior R-values.

[0011] 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 and interior or exterior surface and able to insulate over the mass of the structural wall. Such a system should provide a continuous insulation layer of vacuum insulation panels without breaks. Mounting hardware for the vacuum insulation panels should maintain the integrity of the core of each panel to prevent thermal transfer through the insulation layer. Mounting hardware for the vacuum insulation panels should be inexpensive, easy to install and avoid thermal bridging to achieve improved heating and / or cooling efficiency. The present invention addresses these problems, as well as others associated with insulation systems.

[0012] Summary of the Invention

[0013] The present invention is directed to an insulation system, typically mounted to a wall of a building structure. Although applied to an exterior surface of a wall in a representative installation, the insulation system is suited for many types of applications for new construction, as well as part of remodeling projects and may be retrofit into existing structures. The insulation system improves insulating performance when installed on the exterior with increased mass of the structure in 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, over the top of roof sheathing, existing roof shingles, and / or to an inner surface below a roof. 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.

[0014] The insulation system generally includes an insulation layer formed of a series of insulation panels applied against the wall. The insulation layer are foam insulation panels, such as rectangular panels, having a high R-value. In one embodiment, the insulation panels are vacuum insulation panels. Such vacuum insulation panels are lightweight and have a high insulating efficiency. Exemplary panels are available from Kingspan Insulation LLC of Atlanta, Georgia under the tradename OPTIM-R. Such panels have a microporous core in which the air is evacuated creating a vacuum and the core is encased and sealed in a thin, gas-tight envelope. The panels have the advantages of outstanding thermal properties and a thin configuration. A typical panel having a thickness of 20mm (0.96 inches) has an R-value of 26 and a 50mm thick panel has an R-value of 60. Sealant may be injected between the panels to ensure a continuous insulation layer for moisture control and to prevent thermal bridging across the layer of insulation panels. Panel mounting assemblies are distributed in a spaced apart pattern on the wall. Attachment elements, such as furring strips, for mounting exterior cladding may extend in parallel, either vertically or horizontally. The outer layer attachment elements, mount to an outer surface of the panel mounting assemblies. Cables, tubing, wiring or other lines may be routed against the wall before being covered by the insulation system. Utility boxes and other devices may be fastened to furring strips or before the insulation system is installed, or spaces created with panels of assorted sizes and injectable sealant / foam insulation.

[0015] The panel mounting assemblies are configured for mounting at comers of the typically rectangular vacuum insulation panels. Therefore, each of the panel mounting assemblies may support corners of four vacuum insulation panels. The panel mounting assemblies are aligned so an upper face of each of the panel mounting assemblies receives one of the furring strips.

[0016] Each panel mounting assembly includes a pair of opposed retainer clip devices attaching to a retainer assembly base. The retainer clips are mountable at vertically adjustable positions along the retainer assembly base to accommodate insulation panels having different thicknesses. An upper mounting element attaches to an upper engagement edge of the retainer assembly base. When the panel mounting assemblies are assembled, the upper mounting element is spaced apart from the retainer clips.

[0017] In one embodiment, the retainer clips are configured to be used in pairs mounting in a back-to-back arrangement on either side of a retainer assembly base. In other configurations, a single retainer clip may be used to slides onto and couples to the retainer assembly base. Each retainer clip has a generally planar panel engagement portion configured to engage an outer face of an insulation panel. A pressure balanced runner portion provides structural integrity and easier molding. Injection ports provide for injecting sealant, such as a foam insulation, between the insulation panels and into any voids created by the panel mounting assemblies and to create a moisture barrier and to prevent thermal bridging. Transverse support gussets engage the panel engagement portion and obliquely extending braces. Wire clips are resilient and provide for sliding wiring and other tubing or lines under a flexing end of the clip. Although three wiring clips are shown, the retainer clips may include fewer or more clips, and the clips may be mounted in other positions as may be needed for other applications and routing requirements. Insulation sealant blackout plates extend vertically from an inner edge of the panel engagement portion. A center channel is configured to receive a complementary transverse portion of the retainer assembly base. The center channel includes a widened section that receives a complementary portion of the retainer assembly base. A zip lock engages a complementary portion of the retainer assembly base and provides for setting a vertical position of the retainer clip relative to the retainer assembly base.

[0018] The retainer assembly base includes a bottom planar portion, a planar body extending longitudinally along and vertically from the bottom planar portion, and a transverse portion, extending vertically from the bottom planar portion at a midpoint of the planar body and transverse to the planar body. The planar body includes apertures allowing spray foam / sealant to pass through and to interlock with the panel retainer assemblies. An upper portion of the planar body includes alternating mounting fingers forming spaces and vertical engagement surfaces, for engaging the upper mounting element, as explained hereinafter. A snap lock channel is configured as a notch formed near the top of the transverse portion and is configured to engage complementary portions of the upper mounting element. Opposed slide protrusions extend substantially vertically on each face of the transverse portion and engage widened portions of the center channel of each of the retainer clips. A lead in portion at the top of each slide protrusion aids in aligning the retainer clip when coupling to the retainer assembly base. A ratchet type zip locking portion extends vertically along the vertical edges of the transverse portion to be engaged by a zip lock of a corresponding retainer clip. The bottom portion of the retainer assembly base includes mounting portions for receiving hardware for mounting the panel retainer assemblies to a substrate. For some applications, for mounting to a ferromagnetic surface, the bottom portion may incorporate magnets. The magnets should be sufficiently strong to hold the panel retainer assemblies in place while adhesive permanently sets. It can be appreciated that the bottom portion of the retainer assembly base includes dovetail locking ribs. The locking ribs form channels that may receive adhesive or sealant and create a mechanical interlocking connection.

[0019] The upper mounting element is configured to mount to an upper end of the panel retainer assembly base. The upper mounting element includes a planar plate portion. The planar plate portion includes interlock slots extending through the face of the plate portion. The slots are spaced longitudinally along a centerline of the plate portion. When mounted to the retainer assembly base, the mounting fingers of the planar body of the retainer assembly base extend in the slots and the vertical mounting surfaces engage ends of the slots. Opposed tab locks extend from an underside of the plate portion and form a channel with the plate portion. The tab locks engage the complementary snap lock channels formed in opposed edges of the transverse portion of the retainer assembly base.

[0020] To assemble an insulation retainer assembly, a portion of the transverse portion of each of retainer assembly base is inserted into the center channel of the corresponding retainer clip. The lead in portion on the transverse portion is aligned with the widened portion of the center channel. Each retainer clip is slid along the slide protrusion until the zip lock of the retainer clip engages the complementary ratchet portion of the transverse portion at the proper position of the retainer clip relative to the retainer assembly base. The upper mounting element is attached to the retainer assembly base by aligning each of the tab locks with the corresponding snap lock. The mounting portion is pushed downward onto the upper edge of the planar body so that the tab locks engage angled edges of the transverse portion and flex slightly outward until snapping back into place and engaging the snap lock channels. Simultaneously, the mounting fingers insert into the corresponding slots of the upper mounting portion.

[0021] The mounting and structural elements for mounting siding include the wall, which may be a structural load bearing wall with the panel mounting assemblies mounted against the wall or other surface. Furring strips attach to the mounting plates of the panel retainer assemblies, which are exposed to receives the siding attachment elements. 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. These elements achieve a rigid framework for and exterior protection that provides bracing and support for the outer layer.

[0022] In one embodiment, the elements of the panel mounting assemblies are molded plastic or made of other materials that preferably have a low thermal transfer rate and prevent thermal bridging across the insulation layer for improved heating and / or cooling. The panel mounting assemblies 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 water damage, mold and other problems that conventional building techniques are prone to, especially when set in a damp environment. The distance between panel mounting assemblies may be varied depending upon the application and the type and size of the insulation panels. Moreover, multiple mounting patterns may be utilized to meet the particular requirements of the installation. The panel mounting assemblies are sized to be sufficiently tall so that the upper mounting portion protrudes beyond the thickness of the insulation layer and provides a surface for attaching the siding mounting elements as is required for the particular type of construction.

[0023] 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.

[0024] Brief Description of the Drawings

[0025] Figure l is a perspective view of an exterior of a building having first embodiment of an insulation system having horizontal furring strips according to the principles of the present invention;

[0026] Figure 2 is a perspective view of the wall and the insulation system shown in Figure 1;

[0027] Figure 3 is a side sectional view of the wall and the insulation system shown in Figure 2;

[0028] Figure 4 is an exploded perspective view of the wall and insulation system shown in Figure 2;

[0029] Figure 5 is a perspective view of an insulation mounting bracket and a portion of the insulation system shown in Figure 2;

[0030] Figure 6 is a side view of an insulation mounting bracket and a portion of the insulation system shown in Figure 2;

[0031] Figure 7 is a perspective view of the insulation system shown in Figure 2 partially assembled with foam insulation, panel mounting assemblies and furring strips, and without an exterior layer; Figure 8 is a perspective view of a portion of the insulation system shown in Figure 7;

[0032] Figure 9 is an exploded perspective view of a portion of the insulation system shown in Figure 7;

[0033] Figure 10 is an exploded side view of a portion of the insulation system shown in Figure 7;

[0034] Figure 11 is a perspective view of the insulation system shown in Figure 2 partially assembled with foam insulation, panel mounting assemblies and wiring, and without furring strips or an exterior layer;

[0035] Figure 12 is a perspective view of a panel mounting assembly installed in the partially assembled insulation system shown in Figure 11;

[0036] Figure 13 is a perspective view of an exterior of a building having second embodiment of an insulation system with vertical furring strips according to the principles of the present invention;

[0037] Figure 14 is a side sectional view of the wall and the insulation system shown in Figure 13;

[0038] Figure 15 is a side view of an insulation mounting bracket and a portion of the insulation system shown in Figure 13;

[0039] Figure 16 is an exploded perspective view of a portion of the insulation system shown in Figure 13;

[0040] Figure 17 is an exploded side view of a portion of the insulation system shown in Figure 13;

[0041] Figure 18 is a perspective view of the insulation system shown in Figure 2 partially assembled with foam insulation, panel mounting assemblies and furring strips, and without an exterior layer;

[0042] Figure 19 is a perspective view of the insulation system shown in Figure 2 partially assembled with foam insulation, panel mounting assemblies, and without furring strips or an exterior layer;

[0043] Figure 20 is a first perspective view of the panel mounting assembly shown in Figure 12;

[0044] Figure 21 is a second perspective view of the panel mounting assembly shown in Figure 20;

[0045] Figure 22 is a first end view of the panel mounting assembly shown in Figure 20;

[0046] Figure 23 is a second end view of the panel mounting assembly shown in Figure 20; Figure 24 is a first partially exploded perspective view of the panel mounting assembly shown in Figure 20;

[0047] Figure 25 is a second partially exploded perspective view of the panel mounting assembly shown in Figure 20;

[0048] Figure 26 is a third partially exploded perspective view of the panel mounting assembly shown in Figure 20;

[0049] Figure 27 is a perspective view of the lower elements of the panel mounting assembly shown in Figure 20;

[0050] Figure 28 is an exploded perspective view of the lower elements of the panel mounting assembly shown in Figure 27;

[0051] Figure 29 is perspective view of a retainer clip for the insulation panel mounting assembly shown in Figure 20;

[0052] Figure 30 is a top plan view of the retainer clip shown in Figure 29;

[0053] Figure 31 is a front elevational view of the retainer clip shown in Figure 29;

[0054] Figure 32 is a side elevational view of the retainer clip shown in Figure 29;

[0055] Figure 33 is a perspective view of a base for the insulation panel mounting assembly shown in Figure 20;

[0056] Figure 34 is a top plan view of the base shown in Figure 33;

[0057] Figure 35 is a front view of the base shown in Figure 33;

[0058] Figure 36 is an end view of the base shown in Figure 33;

[0059] Figure 37 is perspective view of a stud element for the insulation panel mounting assembly shown in Figure 20;

[0060] Figure 38 is a front elevational view of the stud element shown in Figure 37;

[0061] Figure 39 is a top plan view of the stud element shown in Figure 37;

[0062] Figure 40 is a sectional view of the stud element along line 40-40 of Figure 38; and

[0063] Figure 41 is an end view of the stud element shown in Figure 37.

[0064] Detailed Description of the Preferred Embodiment

[0065] Referring now to the drawings and in particular to Figure 1, there is shown an insulation system, generally designated 200 mounted to an outer wall 1002 of a building structure 1000. Although shown applied as an exterior surface of a wall 1002, the insulation system 200 is suited for many types of applications for new construction, as well as part of remodeling projects and may be retrofit into existing structures. Moreover, the insulation system 200 is adaptable to mounting to many surfaces in addition to an outer wall, such as a wall, floor, ceiling, or roof. The insulation system 200 improves insulating performance when installed on the exterior with increased mass of the structure 1000 in the heated or cooled portion on the inside of the insulation system 200. However, the insulation system 200 may be installed on the surfaces of interior sides of walls, or directly on framing. The insulation system 200 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 200 may be fixed to floors, ceilings and / or to an inner surface below a roof. As explained hereinafter, in some embodiments the insulation system 200 may be adapted for attachment to metal structures such as pole buildings or intermodal shipping containers.

[0066] Referring to Figures 2-6, the insulation system 200 generally includes an insulation layer formed of a plurality of insulation panels 202 applied against the wall 1002. The insulation layer 202 are foam insulation panels, such as rectangular panels, having a high R- value. In one embodiment, the insulation panels 202 are vacuum insulation panels. Such vacuum insulation panels are lightweight and have a high insulating efficiency. Such panels are available from Kingspan Insulation LLC of Atlanta, Georgia under the tradename OPTIM-R. Such panels have a microporous core in which the air is evacuated creating a vacuum and the core is encased and sealed in a thin, gas-tight envelope. This process gives outstanding thermal properties and a thin solution. A typical panel having a thickness of 20mm (0.96 inches) has an R-value of 26 and a 50mm thick panel has an R-value of 60. Sealant may be injected between the panels to ensure a continuous insulation layer for moisture control and to prevent thermal bridging across the layer of insulation panels. Panel mounting assemblies 212 are distributed in a spaced apart pattern on the wall 1002. Attachment elements, such as furring strips 208, for mounting an exterior layer 204, may extend horizontally in parallel, as shown in Figures 1-6. However, in an alternate mounting configuration shown in Figures 10-16 and 18-19, furring strips 206 extend vertically in parallel. Other attachment elements may have different configurations. The mounting strips 206 or 108, or other attachment elements, mount to an outer surface of the panel mounting assemblies 212. As shown in Figures 11 and 18, cables, tubing, wiring or other lines 210 may be routed against the wall 1002 before being covered by the insulation system 200. Atypical routing of wiring 210 is shown extending vertically and horizontally, but other routing configurations are foreseen. Spaces for receiving electrical boxes and other common wall-mounted devices can be cut into the insulation 202 and exterior layer 204 using a standard drywall keyhole saw or other conventional techniques.

[0067] As shown in Figures 7, 11 and 12, the panel mounting assemblies 212 are configured for mounting at corners of the typically rectangular vacuum insulation panels 202. Therefore, each of the panel mounting assemblies 212 supports corners of four vacuum insulation panels 202. The panel mounting assemblies 212 are aligned so an upper face of each of the panel mounting assemblies 212 receives one of the furring strips 206 or 208.

[0068] Referring now to Figures 20-28, each panel mounting assembly 212 includes a pair of opposed retainer clips 230 attaching to a retainer assembly base 250. The retainer clips 230 are mountable at vertically adjustable positions along the retainer assembly base 250 to accommodate insulation panels 202 having different thicknesses. An upper mounting element 290 attaches to an upper engagement edge of the retainer assembly base 250. When the panel mounting assemblies 212 are assembled, the upper mounting element 290 is spaced apart from the retainer clips 230.

[0069] The retainer clips are configured to be used in pairs mounting in a back-to-back arrangement on either side of a retainer assembly base 250. Referring to Figures 29-32, each retainer clip 230 has a generally planar panel engagement portion 232 configured to engage an outer face of an insulation panel 202. A pressure balanced runner portion 234 provides for some structural integrity and a path for foam adhesive / sealant to ensure that any gaps / voids around the four intersecting panels 202 and the surfaces of the retainer assembly 212 are filled and the surfaces, including sides and faces, are sealed. Injection ports 236 provide for injecting sealant, such as a foam insulation between the insulation panels 202 and into any voids created by the panel mounting assemblies 212 and to create a moisture barrier and to prevent thermal bridging. Transverse support gussets 238 engage the panel engagement portion 232 and obliquely extending braces 246. Wire clips 242 are resilient and provide for sliding wiring and other tubing or lines under a flexing end of the clip 242. Although three wiring clips 242 are shown, the retainer clips may include fewer or more clips, and the clips may be mounted in other positions as may be needed for other applications and routing requirements. Depending upon the application, tape or other house wrap may be placed over seams along the vacuum insulation panels 202 and the wire clips may need to be positioned elsewhere and the wiring routed differently. Voids at the tape or other wrap are filled by the foam sealant / insulation injected through the ports 236. Insulation sealant blackout plates 244 extend vertically from an inner edge of the panel engagement portion 232. A center channel 240 is configured to receive a complementary transverse portion of the retainer assembly base 250. As shown in Figures 29 and 30, the center channel includes a widened section 240A that receives a complementary portion of the retainer assembly base 250. A zip lock 248 engages a complementary portion of the retainer assembly base 250, as explained hereinafter and provides for setting a vertical position of the retainer clip 230 relative to the retainer assembly base 250.

[0070] Referring now to Figures 33-36, the retainer assembly base 250 includes a bottom planar portion 252, a planar body 254 extending longitudinally along and vertically from the bottom planar portion 252, and a transverse portion 256, extending vertically from the bottom planar portion 252 at a midpoint of the planar body 254 and transverse to the planar body. The planar body 254 includes rectangular apertures 260 allowing spray foam / sealant to pass through and to interlock with the panel retainer assemblies. The blackout plates 244 keeps the sealant from escaping through the apertures 260 into the gap 214 while the foam sealant may flow to the other side of the retainer assembly 212 and fill voids and gaps. An upper portion of the planar body 254 includes alternating mounting fingers 264 forming spaces and vertical engagement surfaces 262, for engaging the upper mounting element 290, as explained hereinafter. A snap lock channel 266 is a notch formed near the top of the transverse portion 256 and is configured to engage complementary portions of the upper mounting element 290. Opposed slide protrusions 268 extend substantially vertically on each face of the transverse portion 256 and engage widened portions 240A of the center channel 240 of each of the retainer clips 230. A lead in portion 278 at the top of each slide protrusion 268 aids in aligning the retainer clip 230 when coupling to the retainer assembly base 250. A ratchet type zip locking portion 270 extends vertically along the vertical edges of the transverse portion 270 to be engaged by a zip lock of a corresponding retainer clip. The bottom portion 252 includes mounting portions 276 for receiving hardware for mounting the panel retainer assemblies 212 to the wall or substrate 1002. For some applications, for mounting to a ferromagnetic surface, the bottom portion 252 may incorporate magnets 284. The magnets 284 should be sufficiently strong to hold the panel retainer assemblies 212 in place while adhesive permanently sets. It can be appreciated that the bottom portion 252 of the retainer assembly base 250 includes dovetail locking ribs 272. The locking ribs 272 form channels that may receive adhesive or sealant and create a mechanical interlocking connection. The upper mounting element 290 is configured to mount to an upper end of the panel retainer assembly base 250. As shown in Figures 37-41, the upper mounting element 290 includes a planar plate portion 292. The planar plate portion includes interlock slots 294 extending through the face of the plate portion 292. The slots 294 are spaced longitudinally along a centerline of the plate portion 292. When mounted to the retainer assembly base 250, the mounting fingers 264 of the planar body 254 of the retainer assembly base 250 extend in the slots 294 and the vertical mounting surfaces 262 engage ends of the slots 250. Opposed tab locks 296 extend from an underside of the plate portion 292 and form a channel with the plate portion, as shown in Figure 41. The tab locks 292 engage the complementary snap lock channels 266 formed in opposed edges of the transverse portion 256 of the retainer assembly base.

[0071] To assemble an insulation retainer assembly 212, a portion of the transverse portion 256 of each of retainer assembly base 250 is inserted into the center channel of the corresponding retainer clip 230. The lead in portion 278 on the transverse portion 256 is aligned with the widened portion 240A of the center channel 240. Each retainer clip 230 is slid along the slide protrusion 268 until the zip lock 248 of the retainer clip 230 engages the complementary ratchet portion 270 of the transverse portion 256 at the proper position of the retainer clip relative to the retainer assembly base 250 to obtain a partially assembled structure, such as shown in Figures 26 and 27. The upper mounting element 290 is attached to the retainer assembly base 250 by aligning each of the tab locks 296 with the corresponding snap lock 266. The mounting portion 290 is pushed downward onto the upper edge of the planar body 254 so that the tab locks 296 engage angled edges of the transverse portion and flex slightly outward until snapping back into place and engaging the snap lock channels 266. Simultaneously, the mounting fingers 264 insert into the corresponding slots 294 of the upper mounting portion 290.

[0072] As shown in Figure 8, a typical wiring configuration has the wiring 210 passing along the bottom portion 252 of the retainer assembly base 250 and passing through one or more of the wiring clips 242. However, other configurations are foreseen depending on the routing of the wiring or other lines 210.

[0073] The mounting and structural elements for mounting siding 204 include the wall 1002, which may be a structural load bearing wall with the panel mounting assemblies 212 mounted against the wall 1002 or other surface. Furring strips 206 or 208 attach to the mounting plates 290 of the panel retainer assemblies 212, which are exposed to receives the siding attachment elements. An exterior layer 204, typically siding such as cladding, stucco, brick, veneers or other exterior layers, depending upon the application and requirements, is attached to the furring strips or mounting elements. A gap 214 may be formed between the insulation 202 and the exterior layer 204. The gap 214 allows airflow and to promote drying from water that might breach the exterior cladding 204. The gap 214 allows unobstructed airflow in any direction around all openings and penetrations and allows the furring strips 206 or 208 to dry more quickly. The gap 214 may also allow air to enter from a bottom of the insulation system 202 and flow all the way to a ridge vent at the roof. For some embodiments with the vacuum insulation panels 202, the gap 214 should be 1.5-2 inches thick to provide an extra safety factor to prevent overdriven fasters used for attaching the exterior layer 204 to the attachment strips 206 or 208 from penetrating into a vacuum insulation panel 202. The increased space also provides for mounting perpendicular furring strips over the first layer of furring strips 206 or 208 or for mounting an additional layer of furring strips directly onto the first layer 206 or 208 for receiving hardware to mount the exterior layer 204. The elements 1002, 212, 206 or 208, and 204 achieve a rigid framework for and exterior protection that provides bracing and support for the exterior layer 204.

[0074] In one embodiment, the elements 252, 254 and 256 of the panel mounting assemblies 212 are molded plastic or made of other materials that have a low thermal transfer rate and prevent thermal transfer across the insulation layer. The panel mounting assemblies 212 are also lightweight and impervious to water for durable and inexpensive construction. It can be appreciated that the insulation system 200 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 202 may include openings or capillary channels that are configured to keep moisture away from other layers that may be damaged by moisture. The distance between panel mounting assemblies 212 may be varied depending upon the application and the type and size of the insulation panels 202. Although shown mounted in a rectangular grid with panel mounting assemblies 212 aligned in vertical columns and horizontal rows, other mounting patterns may be utilized to meet the particular requirements of the installation. The panel mounting assemblies 212 are sized to be sufficiently tall so that the upper mounting portion 290 protrudes beyond the thickness of the insulation layer 202 and provides a surface for attaching the furring strips 206 or 208 or mounting elements as is required for the particular type of construction.

[0075] 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 comprising a plurality of vacuum insulation panels, each of the vacuum insulation panels having an inner face, an outer face, and sides extending from the inner face to the outer face; a plurality of panel retaining assemblies mounted to the substrate in a spaced apart arrangement, each of the panel retaining assemblies comprising panel engaging surfaces and a mounting surface spaced apart from the panel engaging surfaces; the mounting surface being spaced beyond the outer face of the vacuum insulation panels; attachment elements mounting to the mounting surfaces of the panel retaining assemblies; and an exterior layer mounted to the attachment elements, the exterior layer and the insulation layer forming a gap.

2. The insulation system according to claim 1, wherein each of the panel retaining assemblies comprises: a retainer assembly base; a pair of retainer clips coupled to sides of the retainer assembly base; an upper mounting plate coupled to a top of the retainer assembly base spaced apart from the retainer clips; wherein the retainer clips and the retainer assembly base form surfaces for engaging the vacuum insulation panels; and wherein the upper mounting plate forms the mounting surface for engaging one of the attachment elements.

3. The insulation system according to claim 2, wherein retainer assembly base comprises planar longitudinal section extending horizontally and longitudinally above a bottom planar portion, and a planar transverse section extending horizontally above the bottom planar portion transverse to the planar longitudinal section.

4. The insulation system according to claim 2, wherein the transverse section comprises slots for engaging the retainer clips, and a top of the planar longitudinal section and the planar transverse portion support the upper mounting plate.

5. The insulation system according to claim 2, wherein the retainer clips comprises planar portions extending parallel to and spaced apart from the bottom portion of the retainer assembly base.

6. The insulation system according to claim 2, wherein the retainer clip comprises a sealant injection port.

7. The insulation system according to claim 2, wherein the planar portions of the retainer clips engage the outer face of the vacuum insulation panels, the bottom portion of the retainer assembly base engages the inner face of the vacuum insulation panels, and the planar longitudinal section and the planar transverse section engage the sides of the vacuum insulation panels.

8. The insulation system according to claim 2, wherein each of the retainer clips comprises a zip lock engaging a slot in the planar transverse section of the assembly base.

9. The insulation system according to claim 8, wherein each of the retainer clips comprises a zip lock engaging a slot in the planar transverse section of the assembly base at a desired position along the slot.

10. The insulation system according to claim 2, wherein the upper mounting plate comprises a tab lock and the planar transverse portion of the retainer assembly base comprises notches engaging the tab lock.

11. An insulation panel retaining assembly comprising: a retainer assembly base; a pair of retainer clips coupled to sides of the retainer assembly base; an upper mounting plate coupled to a top of the retainer assembly base spaced apart from the retainer clips;wherein the retainer clips and the retainer assembly base form surfaces for engaging insulation panels; and wherein the upper mounting plate forms the mounting surface for engaging one of the attachment elements.

12. The insulation panel retaining assembly according to claim 11, wherein retainer assembly base comprises planar longitudinal section extending horizontally and longitudinally above a bottom planar portion, and a planar transverse section extending horizontally above the bottom planar portion transverse to the planar longitudinal section.

13. The insulation panel retaining assembly according to claim 11, wherein the transverse section comprises slots for engaging the retainer clips, and a top of the planar longitudinal section and the planar transverse portion support the upper mounting plate.

14. The insulation panel retaining assembly according to claim 11, wherein the retainer clips comprises planar portions extending parallel to and spaced apart from the bottom portion of the retainer assembly base.

15. The insulation panel retaining assembly according to claim 11, wherein the retainer clip comprises a sealant injection port.

16. The insulation panel retaining assembly according to claim 11, wherein the planar portions of the retainer clips are configured to engage an outer face of the insulation panels, the bottom portion of the retainer assembly base is configured to engage an inner face of the insulation panels, and the planar longitudinal section and the planar transverse section are configured to engage the sides of the insulation panels.

17. The insulation panel retaining assembly according to claim 11, wherein each of the retainer clips comprises a zip lock engaging a slot in the planar transverse section of the assembly base.

18. The insulation panel retaining assembly according to claim 17, wherein each of the retainer clips comprises a zip lock engaging a slot in the planar transverse section of the assembly base at a desired position along the slot.

19. The insulation panel retaining assembly according to claim 11, wherein the upper mounting plate comprises a tab lock and the planar transverse portion of the retainer assembly base comprises notches engaging the tab lock.

20. The insulation panel retaining assembly according to claim 11, further comprising a clip to retain wiring or other lines.

21. The insulation panel retaining assembly according to claim 11, wherein the retainer clips are adjustably couplable to the retainer assembly base.

22. An insulation system mounting to a substrate, comprising: an insulation layer comprising a plurality of insulation panels, each of the insulation panels having an inner face, an outer face, and sides extending from the inner face to the outer face; a plurality of panel retaining assemblies mounted to the substrate in a spaced apart arrangement, each of the panel retaining assemblies comprising panel engaging surfaces and a mounting surface spaced apart from the panel engaging surfaces; the mounting surface being spaced beyond the outer face of the insulation panels; wherein each of the panel retaining assemblies comprises: a retainer assembly base, a pair of retainer clips coupled to sides of the retainer assembly base, an upper mounting plate coupled to a top of the retainer assembly base spaced apart from the retainer clips, wherein the retainer clips and the retainer assembly base form surfaces for engaging the insulation panels, and wherein the upper mounting plate forms the mounting surface for engaging one of the attachment elements; attachment elements mounting to the mounting surfaces of the panel retaining assemblies; andan exterior layer mounted to the attachment elements, the exterior layer and the insulation layer forming a gap.

23. The insulation system according to claim 22, wherein the insulation panels comprise vacuum insulation panels.

24. The insulation panel retaining assembly according to claim 22, wherein the retainer clips are adjustably couplable to the retainer assembly base.

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