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AU2013307299B2 - Apparatus for securing insulation panels to a supporting structure and ceiling support assembly incorporating the same - Google Patents

Apparatus for securing insulation panels to a supporting structure and ceiling support assembly incorporating the same Download PDF

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Publication number
AU2013307299B2
AU2013307299B2 AU2013307299A AU2013307299A AU2013307299B2 AU 2013307299 B2 AU2013307299 B2 AU 2013307299B2 AU 2013307299 A AU2013307299 A AU 2013307299A AU 2013307299 A AU2013307299 A AU 2013307299A AU 2013307299 B2 AU2013307299 B2 AU 2013307299B2
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AU
Australia
Prior art keywords
supporting structure
bracket
panels
depth stop
abutment surface
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
AU2013307299A
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AU2013307299A1 (en
Inventor
Kevin Weeks
Matthew Weeks
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Weeks Holdings Pty Ltd
Original Assignee
Weeks Holdings Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2012904171A external-priority patent/AU2012904171A0/en
Application filed by Weeks Holdings Pty Ltd filed Critical Weeks Holdings Pty Ltd
Priority to AU2013307299A priority Critical patent/AU2013307299B2/en
Publication of AU2013307299A1 publication Critical patent/AU2013307299A1/en
Application granted granted Critical
Publication of AU2013307299B2 publication Critical patent/AU2013307299B2/en
Ceased legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38Connections for building structures in general
    • E04B1/388Separate connecting elements
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D13/00Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights
    • E04D13/16Insulating devices or arrangements in so far as the roof covering is concerned, e.g. characterised by the material or composition of the roof insulating material or its integration in the roof structure
    • E04D13/1606Insulation of the roof covering characterised by its integration in the roof structure
    • E04D13/1612Insulation of the roof covering characterised by its integration in the roof structure the roof structure comprising a supporting framework of roof purlins or rafters
    • E04D13/1637Insulation of the roof covering characterised by its integration in the roof structure the roof structure comprising a supporting framework of roof purlins or rafters the roof purlins or rafters being mainly insulated from the interior, e.g. the insulating material being fixed under or suspended from the supporting framework
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/7675Insulating linings for the interior face of exterior walls
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/78Heat insulating elements
    • E04B1/80Heat insulating elements slab-shaped
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38Connections for building structures in general
    • E04B1/388Separate connecting elements
    • E04B2001/389Brackets
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B9/00Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
    • E04B9/18Means for suspending the supporting construction
    • E04B9/183Means for suspending the supporting construction having a lower side adapted to be connected to a channel of the supporting construction
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/07Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0801Separate fastening elements
    • E04F13/0803Separate fastening elements with load-supporting elongated furring elements between wall and covering elements
    • E04F13/0805Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and the wall
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16BDEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B35/00Screw-bolts; Stay-bolts; Screw-threaded studs; Screws; Set screws
    • F16B35/04Screw-bolts; Stay-bolts; Screw-threaded studs; Screws; Set screws with specially-shaped head or shaft in order to fix the bolt on or in an object
    • F16B35/041Specially-shaped shafts
    • F16B35/044Specially-shaped ends

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Electromagnetism (AREA)
  • Acoustics & Sound (AREA)
  • Building Environments (AREA)

Abstract

(12) INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY (PCT) (19) World Intellectual Property Organization International Bureau (10) International Publication Number (43) International Publication Date W O 2014/047684 Al 3 April 2014 (03.04.2014) WI PO I P CT (51) International Patent Classification: (72) Inventors: WEEKS, Matthew; 40 Barfield Crescent, E04B 9/18 (2006.01) E04F 13/07 (2006.01) Elizabeth, South Australia 5113 (AU). WEEKS, Kevin; E04B 9/22 (2006.01) F16B 35/04 (2006.01) 40 Barfield Crescent, Elizabeth, South Australia 5113 E04B 1/62 (2006.01) (AU). (21) International Application Number: (74) Agent: LESICAR MAYNARD ANDREWS; PO Box PCT/AU2013/001098 2545, Kent Town, South Australia 5071 (AU). (22) International Filing Date: (81) Designated States (unless otherwise indicated, for every 25 September 2013 (25.09.2013) kind of national protection available): AE, AG, AL, AM, AO, AT, AU, AZ, BA, BB, BG, BH, BN, BR, BW, BY, (25) Filing Language: English BZ, CA, CH, CL, CN, CO, CR, CU, CZ, DE, DK, DM, (26) Publication Language: English DO, DZ, EC, EE, EG, ES, Fl, GB, GD, GE, GH, GM, GT, HN, HR, HU, ID, IL, IN, IS, JP, KE, KG, KN, KP, KR, (30) Priority Data: KZ, LA, LC, LK, LR, LS, LT, LU, LY, MA, MD, ME, 2012904171 25 September 2012 (25.09.2012) AU MG, MK, MN, MW, MX, MY, MZ, NA, NG, NI, NO, NZ, (71) Applicant: WEEKS HOLDINGS PTY LTD [AU/AU]; OM, PA, PE, PG, PH, PL, PT, QA, RO, RS, RU, RW, SA, 40 Barfield Crescent, Elizabeth, South Australia 5113 SC, SD, SE, SG, SK, SL, SM, ST, SV, SY, TH, TJ, TM, (AU). TN, TR, TT, TZ, UA, UG, US, UZ, VC, VN, ZA, ZM, Zw. (84) Designated States (unless otherwise indicated, for every kind of regional protection available): ARIPO (BW, GH, [Continued on next page] (54) Title: APPARATUS FOR SECURING INSULATION PANELS TO A SUPPORTING STRUCTURE AND CEILING SUP PORT ASSEMBLY INCORPORATING THE SAME (57) Abstract: An apparatus for securing insulation panels to a supporting structure and having an elongate body and a first end including a tip configured to pierce into the insulation panel and into the supporting structure. The apparatus further includes a depth stop disposed along the elongate body and adjacent said tip the depth stop 56 providing a first abutment surface for a face of said supporting structure and a second 23 end having associated therewith a second abutment surface, whereby a distance between the first abutment surface and the second abutment surface is less than or 20 equal to a minimum thickness of said insulation panels. 32/36 j W O 2 0 1 4 /0 4 7 6 8 4 A 1 l llll|||1ll|||1lllllllllllll1||||||||||||||||||||||||||||||1 ||||||||||||||||||||||||||||||||| GM, KE, LR, LS, MW, MZ, NA, RW, SD, SL, SZ, TZ, SM, TR), OAPI (BF, BJ, CF, CG, CI, CM, GA, GN, GQ, UG, ZM, ZW), Eurasian (AM, AZ, BY, KG, KZ, RU, TJ, GW, KM, ML, MR, NE, SN, TD, TG). TM), European (AL, AT, BE, BG, CH, CY, CZ, DE, DK, EE, ES, Fl, FR, GB, GR, HR, HU, IE, IS, IT, LT, LU, Published: LV, MC, MK, MT, NL, NO, PL, PT, RO, RS, SE, SI, SK, - with international search report (Art. 21(3))

Description

- 1 APPARATUS FOR SECURING INSULATION PANELS TO A SUPPORTING STRUCTURE AND CEILING SUPPORT ASSEMBLY INCORPORATING THE SAME 5 The present invention relates to an apparatus for securing insulation panels to a face of a supporting structure and, in particular, to a screw apparatus adapted to secure expanded polystyrene foam panels directly to roof truss elements. The invention further relates to a ceiling support assembly incorporating the screw apparatus which ensures that the lower 10 face of a plurality of ceiling support battens are disposed at even, level heights ready for ceiling panel attachment. BACKGROUND OF THE INVENTION The purpose of roof insulation is well known in that it provides some 15 level of environmental control in an area inside a home or building. Typically, a home or building will include a roof structure including a plurality of metal or wooden roof trusses which incorporate horizontally extending roof truss sections to which ceiling panels are directly attached. Insulation is usually provided in the form of ceiling batts adapted to be 20 installed between the horizontally extending roof truss beams above the ceiling panels. The batts serve to reduce heat transfer through the roof, improving comfort and energy efficiency. In more recent years, the use of rigid cellular insulation (RCI) for providing insulation to walls and roof has become growingly popular. For 25 example, the present Applicant has been involved in the development of an expanded polystyrene foam structural panel for such purposes. Benefits to using foam panels include being light-weight, having high insulation properties, and being less prone to causing harm and discomfort to installers. 30 However, the fixing of foam panels directly to the lower face of horizontal roof truss elements using known fastening means has presented - 2 problems. For example, known apparatus for fastening the panels to the roof truss elements often restricts the positioning of panels which makes installation of the panels very cumbersome. This was a result of the panel support apparatus, typically a bracket, being hung from an open edge of 5 the truss section and configured such that the edges of two butting panels were engaged and secured by the support device. The skilled addressee would understand that such a configuration severely limits the positional freedom of the panels. Another problem associated with prior art means of securing 10 insulation panels directly to a supporting truss element is that, mounting of ceiling panels there beneath becomes problematic owing to variations in the thickness of the panels. For example, the foam panel height at one end of the room could be different to the foam panel height at an opposite end of the room, thereby increasing the possibility of sloped or uneven ceiling 15 panels. There is a general need in the industry for an apparatus/assembly capable of securing insulation panels, such as foam insulation panels, directly to supporting structures such as wall stud or roof truss elements, and in the latter case, ensuring that ceiling panels are fixed at even 20 distances relative to the roof truss chords. Any discussions of documents, acts, materials, devices, articles or the like, which has been included in the present specification is solely for the purpose of providing a context for the present invention. It should not be taken as an admission that any or all of the previous discussion forms 25 part of the prior art base or was common general knowledge in the field of the invention as it existed before the priority date or any of the claims herein. SUMMARY OF THE INVENTION - 3 In one aspect, the present invention provides an assembly including: an apparatus configured for securing insulation panels to an overhead supporting structure, the apparatus including: an elongate body; 5 a first end including a tip configured to pierce into the insulation panel and into the supporting structure; a depth stop disposed along the elongate body and adjacent said tip, said depth stop providing a first abutment surface for a face of said supporting structure; and 10 a head portion having associated therewith a second abutment surface, whereby a distance between the first abutment surface and the second abutment surface is less than or equal to a minimum thickness of said insulation panels, wherein: the depth stop is a shoulder formed integrally with the body having 15 of a larger cross sectional dimension than the body. The skilled addressee would understand that in having a body of smaller cross sectional dimension to that of the depth stop, manufacturing costs and thermal bridging from the supporting structure is reduced. This is particularly important when the supporting structure is a truss element. such that if the 20 screw apparatus included a heavy metal body of the same or larger cross section than the depth stop, the ability to transfer heat from the truss element would be greater; and the apparatus including the tip, depth stop, body and head form an integral structure; and 25 a bracket including an upper face configured to be sandwiched between the insulation panel and the head portion of the apparatus, the bracket further including hook means suspended there from for supporting a ceiling support structural member, wherein the bracket is an inverted U- - 4 shaped bracket including a longitudinal upper face and two side walls extending downwardly there from, and the bracket upper face includes a slot having an opening at one end thereof and a linear portion, the linear portion being of a dimension to accommodate sliding of the apparatus 5 elongate body there along but not allowing for retraction of the depth stop, the opening being of a dimension to allow for insertion of the apparatus including the depth stop. In an embodiment, the hook means are in the form of downward extensions of each corner of each side wall into a hook such that each side 10 wall includes two inwardly facing hook sections and each bracket includes four hook sections at lower corners thereof. In an embodiment, the ceiling support structural member is a batten including a lower surface to which a ceiling panel is adapted to be fixed, and upright, slightly diverging side walls which terminate in horizontally 15 extending flanges adapted to be supported inside each pair of inwardly facing hook sections. In an embodiment, the side walls are compressible such that the width of the batten can be manually decreased in order for the flanges to fit between the hook sections, and then engage inside the hook sections by 20 releasing the side walls to their original form. BRIEF DESCRIPTION OF THE DRAWINGS The present invention will now be described with reference to the accompanying drawings which illustrate exemplary embodiments of the present invention, wherein: 25 Fig. 1 is a perspective view of an embodiment of a screw apparatus of the present invention for securing an insulation panel to a roof truss element, - 5 This page intentionally blank - 6 Fig. 2 is a perspective view of an embodiment of a screw apparatus for securing an insulation panel to a roof truss element according to an alternate embodiment; Fig. 3 is a top, perspective view of an embodiment of a ceiling batten 5 support bracket forming part of an assembly of the present invention; Fig. 4 is a top, perspective view of a plurality of roof truss elements including insulation panels propped up against a lower face of the roof truss elements to form an insulating layer; Fig. 5 is a top, perspective view of the roof truss elements and 10 propped insulation panels of Figure 4, and assemblies according to an embodiment of the invention whereby each assembly includes a screw apparatus and a ceiling batten support bracket for securing the panels to the roof truss elements and presenting a means of attachment for a plurality of ceiling support battens; 15 Fig. 6 is a top, cutaway perspective view of the components shown in Figure 5 in a fully assembled state, and ceiling support battens supported at right angles to the direction of the roof truss elements by axially aligned and spaced apart ceiling batten support brackets; Fig. 7 is a top, perspective view of the components of Figure 6 in a 20 fully assembled state, and ceiling panels attachable to a lower face of the ceiling support battens; Fig. 8 is a top, cutaway perspective view of the components of Figure 7 in a fully assembled state; Fig. 9 is a top, perceptive view of the components of Figure 7 in a 25 fully assembled state; Fig. 10 is an enlarged perspective view of an embodiment of an assembly of the invention including a screw apparatus used to secure an - 7 insulation panel to a roof truss element and an associated bracket partially supporting a ceiling support batten to which a ceiling panel is attached; Fig. 11 A is a cross sectional view of an embodiment of an assembly as shown in Figure 10 whereby the bracket is slightly embedded in the 5 insulation panel; Fig. 11 B is a cross sectional view of an embodiment of an assembly as shown in Figure 10 whereby the bracket is flush with a lower face of the insulation panel; and Fig. 12 is a cross sectional view of an embodiment of the invention 10 whereby the roof truss elements are rolled metal sections. DETAILED DESCRIPTION OF EMBODIMENT(s) OF THE INVENTION The following detailed description of the invention refers to the accompanying Figures. Although the description includes exemplary embodiments, other embodiments are possible, and changes may be made 15 to the embodiments described without departing from the spirit and scope of the invention. Wherever possible, the same reference numbers will be used throughout the embodiments and the following description to refer to the same and like parts. Reference to a "structural element", "truss element", "roof truss 20 element" or "wall stud" herein is not intended to limit the invention to any one type, shape or orientation of supporting structure or structural element thereof. For example, in one embodiment, the supporting structure could form part of a roof truss, and thus may include within its scope any type of roof truss element, including rolled steel sections or solid roof truss beams. 25 The invention is not intended to be limited to use of a roof truss element. A truss element may be an upright element such as a wall stud for example. Provided the structure or surface thereof is of a sufficient structural integrity to support multiple components, and presents an attachment face, then it forms a suitable supporting structure as described herein.
- 8 The present invention relates to an apparatus and assembly for securing insulation panels directly to a face of a supporting structure, such as a horizontal roof truss element or an upright wall stud. When secured to an overhead supporting structure, the assembly provides a means for 5 attachment of ceiling panels a spaced distance below the insulating panels. In one aspect, the invention provides an apparatus for securing the insulation panels which overcomes various deficiencies associated with prior art methods of securing the panels. In another aspect, the invention provides an assembly for supporting a plurality of ceiling support battens at 10 a level height. According to one embodiment, the apparatus is in the form of a screw apparatus 10 as shown in Figure 1 including a longitudinal body 12 having a screw head 14 at one end and a threaded section 16 at, or adjacent to, an opposed end. Disposed inwardly of the threaded section 16 15 is a depth stop 18 in the form of a shoulder providing an abutment surface 20. The threaded section 16 shown in Figure 1 is of the type for screwing into a solid roof truss element, but the tip of the apparatus 10 could be configured a number of other ways, including for screwing into thin steel sections and the like as described further below. 20 The distance between the abutment surface 20 and a flat surface 22 associated with the screw head 14 will be referred to herein as the "critical dimension" of the screw apparatus 10. However, use of the word "critical" should in no way be considered limiting, or interpreted as referencing a preferred embodiment of the invention. In addition, the surface 22 need not 25 necessarily be associated with the screw head, but could be in the form a second depth stop for example. A screw apparatus 12 according to an alternate embodiment is shown in Figure 2 whereby the threaded section 16 includes a "self-drilling" type tip 23 for particular use in screwing into rolled metal elements such as 30 the substantially Z-shaped rolled steel element shown in Figure 12, as - 9 opposed to a conventional thread for drilling into solid truss elements as shown in the other drawings The assembly for providing an even surface for installation of ceiling panels, according to one embodiment, includes the screw apparatus 10 of 5 Figure 1 and a ceiling support bracket 24 as shown in Figure 3. The bracket 24 is of an inverted U-shaped, longitudinal dimension including two vertical side walls 26 and an upper wall 28. Each vertical side wall terminates at each lower corner into downwardly extending and inwardly directed hook sections 30 such that there are four hook sections 10 associated with each bracket 24. The hook sections 30 are adapted to suspend and support a ceiling support batten 30 as will be described in more detail below. The upper wall 28 includes a longitudinal slot 32 including at one end a circular opening 34 of sufficient dimension to allow for insertion of the 15 screw apparatus body 12 as well as the depth stop 18, and a linear portion 36 of a sufficient dimension to allow for sliding of the body 12, but not large enough to allow for retraction of the depth stop 18. Further, the upper wall 28 terminates at its longitudinal ends in small downwardly sloped ramps 35 which are intended to assist an installer by allowing the bracket 24 to slide 20 sideways more easily during positioning/tightening, as described in more details below. The way in which the screw apparatus 10 acts to secure an insulation panel to a supporting structure, and thereby overcome some of the deficiencies associated with prior art methods of doing so, will now be 25 described with reference to Figures 4 to 10 which demonstrate step by step the process of installing insulation and ceiling panels to a roof truss in accordance with an embodiment of the present invention. The following paragraphs will also demonstrate how an assembly incorporating both the screw apparatus 10 and the bracket 24 provides for the ceiling panels to be 30 secured at an even height relative to the overhead roof trusses.
- 10 Figure 4 illustrates three horizontal roof truss elements 38 forming part of three roof truss assemblies (not shown in full) with a plurality of foam insulation panels 40. At this stage of installation, the panels are being held in place ready to be fastened or secured to the overhead rood truss 5 elements, and can be held by a ground prop (not shown), or by one or more installers, although the present invention is not intended to be limited to any one of these means of support. In the embodiment shown, the panels include straight side edges which are adapted to abut, but in an alternate embodiment (not shown), the 10 insulation panels could include side edges capable of engaging one another such that sides of the panels may engage with adjacent panels. This would simplify the installation procedure in that one would no longer need to ensure that every panel is individually propped. The next step of insulation is shown in Figure 5 in which the screw 15 apparatus 10 of Figure 1 is shown together with the bracket 24 of Figure 3. This assembly of components is used to secure the insulation panels 40 to the overhead truss elements 38 and, as shown in Figure 5, the screw apparatus 10 is adapted to be inserted through slot 32 of bracket 24. A fitter would insert the screw apparatus into the rounded opening 34 of the 20 bracket slot 32 until the depth stop 18 is fully inserted, and then slide the screw apparatus 10 along the linear portion 36 to an appropriate position, ensuring that the depth stop can no longer be retracted from the slot. Once an installer has partially engaged the screw apparatus 10 with the bracket 24 like so, the screw can be used to pierce the insulation panel 25 by tightening of the screw into the panel surface at a position beneath an overhead roof truss element. The installer continues tightening until the threaded section end of the screw apparatus contacts a lower face 42 of the truss element 38. The installer then would continue to tighten the screw apparatus to thereby pierce the truss element and continue tightening until 30 the depth stop surface 20 abuts the lower face 42 of the truss at which - 11 point further tightening will be opposed by the lower face 42. It is at this time that the installer knows that no further tightening is required. In one embodiment the critical dimension of the screw apparatus body 12 defined earlier is slightly less than the smallest measured 5 thickness of each insulation panel to ensure that the bracket 24 will always create a tight, rattle-free fit in that the bracket becomes slightly embedded in the foam as shown in Figure 11 a. Owing to the nature by which such insulation panels are manufactured, it is estimated that the panel thickness may vary. For 10 example, one panel thickness may vary compared to another panel thickness by up to 3mm or more. The skilled addressee would understand now why the critical dimension of the screw apparatus is an important factor. If the critical dimension is larger than a maximum thickness of the foam panels, the foam panel will be allowed to rattle which is undesirable. If 15 the critical dimension is the same as the thickness of the foam panel, as shown in Figure 11 b, this may still be adequate. However, in an embodiment that ensures that the panel is secured free of movement, this dimension should be made slightly less than the minimum panel thickness. It is also evident in Figure 11 a how the upper face of the bracket 24 20 effectively acts as a washer for the screw apparatus 10 in that it provides an abutting surface for the screw head surface 22. When the insulation panels are propped in position, the installers are unable to see the overhead truss. However, the approximate position of the truss can be estimated in that they are visible at the edge of the panels and 25 they also align with the wall studs (not shown) that are visible from within the building. This is how the installer will know approximately where to pierce the insulation panel to reach the truss element. Fitters are quite accustomed to lining up assemblies like so and it is not envisaged that this will pose a problem. There are also now devices available to send and 30 provide an audible/visible alarm to indicate where a beam is hidden behind a panel.
- 12 Figure 6 illustrates the next step of attaching ceiling support battens to aligned brackets 24 secured beneath the insulation panels. The skilled addressee would understand the importance of having brackets which are secured to the panels in appropriate alignment in order to accommodate a 5 batten. Each batten 44 is substantially U-shaped with a horizontal base 46 and outwardly diverging, upright side walls 48. The side walls terminate in substantially horizontal flanges 50 which are the portions dimensioned to be accommodated and secured inside inwardly directed hook sections 30 of each bracket. 10 When fixed to the insulation panels, each longitudinal bracket is aligned parallel with the longitudinal overhead roof truss element, and the hook sections 30 thereof are configured such that the battens will be accommodated at right angles to the overhead roof truss elements. The slot 32 in the brackets facilitates the alignment of brackets associated with 15 spaced apart roof truss elements in that spaced apart brackets accommodating a single batten are able to be appropriately aligned with one another just prior to final tightening of the screw apparatus' 10. Alignment of spaced brackets can be achieved any number of ways including by laser alignment or by visible inspection. The configuration of 20 each batten is such that the outwardly diverging side walls can be slightly compressed until the batten is appropriately centered inside the hook sections 30 and then released so that the flanges 50 enter the hook sections and are thereby restricted from downward movement. The skilled addressee would appreciate that, in carrying out the 25 abovementioned steps, a plurality of batten support brackets 24 across an entire ceiling are positioned an equal distance away from a lower face of a roof truss element, and battens suspended there from are thus also disposed at an even, level height. The base surface 46 of each batten is then ready to accommodate ceiling panels 52, such as plasterboard 30 panels, as shown in Figure 7.
- 13 The panels 52 can be attached to the base surface 46 of each batten using any conventional means, including by using screw fasteners (not shown). Figures 8 and 9 show the fully assembled and installed views of each of the prior described components. It can be appreciated, in 5 particular in Figure 8, that a clearance is created between the ceiling panels 52 and the foam panels 40 there above. This clearance is equal to substantially the combined height of the engaged bracket 24 and batten 44. In one embodiment, the engaged bracket and batten are dimensioned such that they create an approximately 40mm air cavity 54 10 between the underside of the insulation panels and the top surface of the ceiling panels, allowing for fitment of ceiling fixtures and other utilities (not shown). Figure 10 shows an enlarged view of the fully assembled screw apparatus 10 and an assembly including a screw apparatus 10 and a 15 batten support bracket 24 assembly according to an embodiment. In one embodiment the thickness of the insulation panels ranges between approximately 113mm to 115mm and is constructed of expanded polystyrene foam which allows for the screw to pierce through the panel. In this example embodiment, the critical dimension of the screw apparatus 10 20 may accordingly be 112 millimeters, that is, slightly less than the minimum thickness of the insulation panel. The skilled addressee would understand that the resulting engagement would be similar to that shown in Figure 11 a which, as mentioned earlier, shows the bracket slightly embedded into the foam panel. The invention is in no way intended to be limited to the above 25 described dimensions and/or thickness variations. As mentioned earlier, the present invention is not intended to be limited to any on type of roof truss element. For example, Figure 12 illustrates a further embodiment whereby the roof truss element is a substantially Z-shaped rolled steel truss element 56 and the screw 30 apparatus 10 is of the type shown in Figure 2 adapted for screwing the - 14 thickness of steel as shown. As mentioned earlier, it is to be understood that variations to the type of roof truss element and the means of fastening the apparatus 10 to the truss are considered within the scope of the invention. For example, the truss element could indeed be an upright wall 5 stud. The present invention thus provides an apparatus 10 which overcomes some of the deficiencies associated with prior art methods of securing insulation panels to a supporting structure such as an underside of horizontally extending roof truss elements, in that an installer can simply 10 prop up the panels and pierce the apparatus through the panel and into the truss without the need to ensure that the insulation panels are positioned or arranged in any particular way. That is, the apparatus 10 need not extend alongside edges of abutting panels in order to support the two adjacent panels as was required in prior art apparatus known to the Applicant. 15 In another aspect, the invention provides an assembly including such a screw apparatus 10 in association with a bracket 24 which is clamped to the underside of the foam panel using the aforementioned screw apparatus 10 and configured to provide a support for a plurality of battens extending at right angles to the roof truss elements at even 20 distances from the roof truss elements. That is, a lower surface of each batten provides an even surface across an entire ceiling to which an installer may attach ceiling panels. Thus, insulation and ceiling fitters are able to install ceiling insulation panels to a higher degree of screw position flexibility while maintaining a 25 consistent drop height from the roof truss element, or other supporting structure. In addition, the configuration provides a cavity between the insulation panels and the top surface of the ceiling panels, thereby accommodating any required utilities such as electrical wiring.
- 15 The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement or any suggestion that the prior art forms part of the common general knowledge in Australia.

Claims (4)

1. An assembly including: an apparatus configured for securing insulation panels to an overhead supporting structure said apparatus including: 5 an elongate body; a first end including a tip configured to pierce into the insulation panel and into the supporting structure; a depth stop disposed along the elongate body and adjacent said tip, said depth stop providing a first abutment surface for a face of 10 said supporting structure; and a head portion having associated therewith a second abutment surface, whereby a distance between the first abutment surface and the second abutment surface is less than or equal to a minimum thickness of said insulation panels, wherein: the depth stop is a 15 shoulder formed integrally with the body and has a larger cross sectional dimension than the body; and the apparatus including the tip, depth stop, body and head form an integral structure; and a bracket including an upper face configured to be sandwiched 20 between the insulation panel and the head portion of the apparatus, the bracket further including hook means suspended there from for supporting a ceiling support structural member, wherein the bracket is an inverted U-shaped bracket including a longitudinal upper face and two side walls extending downwardly there from, and 25 wherein the bracket upper face includes a slot having an opening at one end thereof and a linear portion, the linear portion being of a dimension to accommodate sliding of the apparatus elongate body there along but not allowing for retraction of the depth stop, the opening being of a dimension to allow for insertion of the apparatus 30 including the depth stop. - 17
2. An assembly as in claim 1 wherein the hook means are in the form of downward extensions of each corner of each side wall into a hook such that each side wall includes two inwardly facing hook sections and each bracket includes four hook sections at lower 5 corners thereof.
3. An assembly as in claim 2 wherein the ceiling support structural member is a batten including a lower surface to which a ceiling panel is adapted to be fixed, and upright, slightly diverging side walls which terminate in horizontally extending flanges adapted to 10 be supported inside each pair of inwardly facing hook sections.
4. An assembly as in claim 3 wherein the side walls are compressible such that the width of the batten can be manually decreased in order for the flanges to fit between the hook sections, and then engage inside the hook sections by releasing the side walls to their 15 original form. - 18 This page intentionally blank
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AU2012904171A AU2012904171A0 (en) 2012-09-25 Apparatus for securing insulation panels to a supporting structure and ceiling support assembly incorporating the same
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