Insulation structures, systems and methods for uninsulated existing ductwork
View Patent ↗An insulation assembly is provided. The insulation assembly includes a three-sided insulation envelope configured to form a cavity. The cavity is configured to receive a section of uninsulated, existing ductwork. The three-sided insulation envelope forms an opening. An insulation cap is configured to seat against the three-sided insulation envelope thereby encapsulating the uninsulated, existing ductwork and sealing the opening.
1. An insulation assembly comprising: a three-sided insulation envelope configured to form a cavity, the cavity configured to receive a section of uninsulated, existing duct work, the three-sided insulation envelope forming an opening; and a discrete insulation cap, separate and apart from the three-sided insulation envelope is configured to seat against the three-sided insulation envelope thereby encapsulating the uninsulated, existing ductwork and sealing the opening;
wherein the three-sided insulation envelope is formed from a folded duct board.
2. The insulation assembly of claim 1 , wherein the three-sided insulation envelope includes a thermoplastic polymer sheet, a plurality of facing sheets and a layer of foam insulation.
3. The insulation assembly of claim 1 , wherein the insulation cap includes a thermoplastic polymer sheet, a plurality of facing sheets and a layer of foam insulation.
4. The insulation assembly of claim 1 , wherein the three-sided insulation envelope and the insulation cap are formed from the same duct board material.
5. The insulation assembly of claim 1 , wherein the three-sided insulation envelope has chamfered ends.
6. The insulation assembly of claim 1 , wherein the insulation cap has chamfered ends.
7. The insulation assembly of claim 1 , wherein chamfered ends of the three-sided insulation envelope are configured to receive and mate with chamfered ends of the insulation cap.
8. The insulation assembly of claim 1 , wherein edges of the three-sided insulation envelope and the insulation cap are covered with one or more thermoplastic right-angle strips.
9. The insulation assembly of claim 1 , wherein edges of the three-sided insulation envelope and the insulation cap are sealed by welding.
10. The insulation assembly of claim 1 , wherein flanges extending from adjacent sections of uninsulated, existing ductwork are encapsulated by an insulated flange cap.
11. A method of using an insulation assembly comprising the steps of: forming a cavity with a three-sided insulation envelope, the cavity configured to receive a section of uninsulated, existing duct work, the three-sided insulation envelope forming an opening; and seating a discrete insulation cap, separate and apart from the three-sided insulation envelope against the three-sided insulation envelope, thereby encapsulating the uninsulated, existing ductwork and sealing the opening; and including the step of forming the three-sided insulation envelope from a folded duct board.
12. The method of claim 11 , wherein the folded duct board includes a plurality of V-shaped grooves.
13. The method of claim 11 , including the step of forming the three-sided insulation envelope and the insulation cap from the same duct board material.
14. The method of claim 11 , wherein edges of the three-sided insulation envelope and the insulation cap are covered with one or more thermoplastic right-angle strips.
15. An insulation assembly comprising:
a first three-sided insulation envelope configured to form a first cavity, the first cavity configured to receive a first section of uninsulated, existing duct work, the first three-sided insulation envelope forming a first opening;
a second three-sided insulation envelope configured to form a second cavity, the second cavity configured to receive a second section of uninsulated, existing duct work, the second three-sided insulation envelope forming a second opening, the second three-sided insulation envelope seated against the first three-sided insulation envelope;
a first strip configured to cover a first joint between the first three-sided insulation envelope and the second three-sided envelope; and
a second strip configured to cover a second joint between the first three-sided insulation envelope and the second three-sided envelope.
16. The insulation assembly of claim 15 , wherein each of the first three-sided insulation envelope and the second three-sided insulation envelope includes a thermoplastic polymer sheet, a plurality of facing sheets and a layer of foam insulation.
17. The insulation assembly of claim 15 , wherein the first three-sided insulation envelope and the second three-sided insulation envelope are formed from the same duct board material.
18. The insulation assembly of claim 15 , wherein flanges extending from adjacent sections of uninsulated, existing ductwork are encapsulated by an insulated flange cap.