U.S. patent application number 10/041804 was filed with the patent office on 2003-07-10 for thermal deck.
Invention is credited to Ellis, Billy.
Application Number | 20030126806 10/041804 |
Document ID | / |
Family ID | 21918403 |
Filed Date | 2003-07-10 |
United States Patent
Application |
20030126806 |
Kind Code |
A1 |
Ellis, Billy |
July 10, 2003 |
Thermal deck
Abstract
A decking assembly is mounted to a building roof or wall to
thermally insulate the buildingt. The decking assembly has a first
panel with an outside surface and a foil covered inside surface and
a second panel having an outside surface and a foil covered inside
surface. The foil covered inside surface of the second panel faces
the foil covered inside surface of the first panel. At least one
spacer is positioned between the panel so as to create an air space
defined by the foil covered inside surfaces. The air space has an
open inlet and outlet to create a continuous conduit for the flow
of air from an entrance side to an exhaust side. The air space can
be divided into two separate compartments by a barrier panel that
has foil on opposite sides.
Inventors: |
Ellis, Billy; (Joshua,
TX) |
Correspondence
Address: |
James E. Bradley
Bracewell & Patterson, L.L.P.
P.O. Box 61389
Houston
TX
77208-1389
US
|
Family ID: |
21918403 |
Appl. No.: |
10/041804 |
Filed: |
January 8, 2002 |
Current U.S.
Class: |
52/95 ;
52/302.1 |
Current CPC
Class: |
E04D 13/17 20130101;
E04B 7/20 20130101 |
Class at
Publication: |
52/95 ;
52/302.1 |
International
Class: |
E04D 003/40; E04B
007/00; E04D 013/00 |
Claims
What is claimed is:
1. A thermal decking comprising: a first panel; a second panel; a
plurality of spacers positioned between the first and second panels
so as to create an air space between the first and second panels; a
pair of spaced-apart heat radiant layers of foil, each of the
layers of foil having an exposed side located within the air space;
and an inlet to the air space at one end of the first and second
panels and an outlet at an opposite end of the first and second
panels to cause a flow of air from the inlet to the outlet.
2. The thermal decking of claim 1, wherein the spacers are parallel
to each other, each having one end at the inlet and an opposite end
at the outlet.
3. The thermal decking of claim 1, wherein the layers of foil are
mounted to the first and second panels, with their exposed sides
facing each other and the air space being located between the
layers of foil.
4. The thermal decking of claim 1, wherein the first and second
panels are of plywood, the layers of foil being mounted to inside
surfaces of the first and second panels, with their exposed sides
facing each other and the air space being located between the
layers of foil.
5. The thermal decking of claim 1, further comprising a barrier
panel located between and parallel to the first and second panels,
dividing the air space into a primary air space and a secondary air
space; and wherein the layers of foil are mounted to opposite sides
of the barrier panel.
6. The thermal decking of claim 1, wherein the inlet and the outlet
extend across a width of the panels.
7. In a building roof having an inclined supporting structure, with
a lower edge and a peak, a roof decking installed on the supporting
structure, comprising: a first panel of plywood installed on the
supporting structure and extending from the lower edge of the roof
to the peak; a second panel of plywood spaced above the first panel
and extending from the lower edge of the roof to the peak; a
plurality of spacers positioned between the first and second panels
so as to create an air space between the first and second panels,
the spacers being parallel to each other and extending from the
lower edge of the roof to the peak; a pair of spaced apart heat
radiant layers of foil, one of the layers of foil having an exposed
surface facing generally upward and the other of the layers of foil
having an exposed face facing generally downward, the exposed faces
being located within the air space; and an inlet to the air space
at the lower edge of the roof and an outlet at the peak of the roof
to cause a flow of air through the air space from the inlet to the
outlet.
8. The roof according to claim 7, further comprising a rotating air
moving mechanism at the peak for enhancing the flow of air through
the air space from the inlet to the outlet.
9. The roof according to claim 7, wherein the layers of foil are
mounted to the first and second panels, with their exposed sides
facing each other and the air space being located between the
layers of foil.
10. The roof according to claim 7, further comprising a barrier
panel located between and parallel with the first and second
panels, dividing the air space into a primary air space and a
secondary air space; and wherein the layers of foil are mounted to
opposite sides of the barrier panel.
11. A method for insulating a building, comprising: (a) providing
an insulating assembly having a first panel, a second panel, a
plurality of spacers positioned between the first and second panels
so as to create an air space between the first and second panels, a
pair of spaced-apart heat radiant layers of foil, each of the
layers of foil having an exposed side located within the air space,
an inlet to the air space at one end of the first and second panels
and an outlet at an opposite end of the first and second panels;
and (b) mounting the insulating assembly to the building and
causing a flow of air through the air space from the inlet to the
outlet.
12. The method according to claim 11, wherein step (b) comprises
mounting the insulating assembly to a supporting structure of a
roof.
13. The method according to claim 11, wherein step (b) comprises
mounting the insulating assembly to an inclined supporting
structure of a roof, with the inlet being located at a lower edge
of the roof and the outlet being located at a peak of the roof.
14. The method according to claim 11, wherein step (b) further
comprises installing a rotary air moving mechanism to the building
in communication with the outlet, and operating the rotary air
moving mechanism to cause the air flow through the air space.
15. The method according to claim 11, wherein step (b) comprises
mounting the insulating assembly to a supporting structure of a
vertical wall of the building and positioning the inlet adjacent a
foundation of the building.
16. The method according to claim 11, wherein step (b) comprises
mounting the insulating assembly to an inclined supporting
structure of a roof, with the inlet being located at a lower edge
of the roof and the outlet being located at a peak of the roof; and
installing a rotary air moving mechanism at the peak of the
building in communication with the outlet, and operating the rotary
air moving mechanism to cause the air flow through the air space.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates generally to insulating a
house and particularly to insulating a house using decking and
still more particularly to insulating the roof of a house using
insulated decking.
[0003] 2. Description of the Related Art
[0004] The roof system of a conventional residential building
includes uniformly spaced joists spanning the length between pairs
of parallel support beams, the joists forming the ceiling.
Wallboard and 2.times.6 boards may be placed on top of the
uniformly spaced joists. Metal or wood trusses are then erected
above the joists to form the framing for the roof. Exterior plywood
sheathing is applied on top of the trusses and an exterior
covering, such as a roofing felt and either asphalt, metal roofing
or wood shingles, is then secured to the exterior surface of the
sheathing. Often, soffits, or ventilated panels are installed to
allow air to circulate freely, helping prevent problems with
excessive heat or moisture inside the eaves and attic. However,
such ceiling and roof systems can have less than desirable
insulation properties and thus additional insulation is often
used.
[0005] The roof structure of most conventional industrial buildings
typically include rafters, purlins mounted on the rafters, and
sheets of hard metal roofing material mounted over the purlins.
Blankets of insulation material are typically rolled out over the
purlins and sandwiched between the purlins and the sheets of hard
metal roofing material. Examples of such insulated roof structures
are disclosed in U.S. Pat. Nos. 3,559,914, 4,047,345 and
4,147,003.
[0006] It has been proposed to combine sheets of radiant barrier
materials, such as metal foils, between the blankets of insulation
and the roofing material for retarding heat transfer through roof
structures. To provide an effective barrier against heat transfer,
an air space or cavity in which the radiant barrier is positioned
also is needed to enable the foil to reflect heat and retard its
passage through the roof. If the upper blanket of insulation or
other material is in direct contact with the foil, the foil will
tend to conduct heat through the roof and into the building instead
of reflecting or conducting the heat back to the heat source.
[0007] U.S. Pat. No. 2,015,817 to Schmidt and U.S. Pat. No.
2,116,270 to Le Grand disclose heat reflective metal surfaces in
conjunction with air spaces adjacent the same for minimizing the
transfer of heat through the wall surface by radiation. The problem
with such a design is that heat is conducted through the first wood
layer to the foil barrier. Foil is a good conductor but a poor
radiator. As the foil barrier is heated, very little of the heat is
given off in the form of radiation into the air space. Most of the
heat is given off in the form of conduction by convection currents
inside the air space and is allowed to heat the air inside the dead
air space. Once the air space is heated, it is difficult to cool
down and heat is conducted through the second wood layer and into
the building. If a foil barrier is also on the second wood layer,
then some of the heat in the air space may be reflected back into
the air space in the form of radiation while the rest heats the
second foil through conduction with the convection currents. This
conducted heat is further given off in the form of conduction
through the plywood and is allowed to heat the inside of the
building.
[0008] Accordingly, it would be desirable to provide a radiant
barrier material having improved insulation and heat transfer
properties for a residential or industrial building.
BRIEF SUMMARY OF THE INVENTION
[0009] It is an object of the present invention to provide a
radiant barrier material having improved insulation and heat
transfer characteristics for a residential or industrial
building.
[0010] It is another object of the present invention to provide a
radiant barrier system that eliminates static air space which, once
heated, would tend to conduct heat through a second wood layer and
into the building.
[0011] It is yet another object of the present invention to provide
a radiant barrier material that is more efficient and economical to
use.
[0012] The insulating assembly of this invention has a pair of
spaced apart panels separated by spacers to create an air space. A
pair of layers of heat radiant foil are spaced apart from each
other and located in the air space. The assembly has an inlet and
outlet to cause air flow through through the air space.
[0013] In the first embodiment the first panel has an outside
surface and a foil covered inside surface and the second panel has
an outside surface and a foil covered inside surface. The foil
covered inside surfaces face each other and define boundaries of
the air space. After installation of the thermal decking, a rotary
air moving mechanism may be mounted to the building for drawing air
from the inlet to the outlet.
[0014] In a second embodiment, a radiant barrier is positioned
between the two panels. Foil is mounted to opposite sides of the
barrier. The barrier divides the air space into primary and
secondary air spaces.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The novel features believed characteristic of the invention
are set forth in the appended claims. The invention itself however,
as well as a preferred mode of use, will best be understood by
reference to the following detailed description of an illustrative
embodiment when read in conjunction with the accompanying drawings,
wherein:
[0016] FIG. 1 is a cross sectional view of one embodiment of the
thermal decking of the present invention, taken along the line 1-1
of FIG. 1.
[0017] FIG. 2 is a cross sectional view of another embodiment of
the thermal decking of the present invention, taken along the line
2-2 of FIG. 2.
[0018] FIG. 3 is a partial cross sectional view of the thermal
decking of FIG. 1 installed on a residential roof using a
turbine.
[0019] FIG. 4 is a partial cross sectional view of the thermal
decking of FIG. 2 installed on a residential roof and wall system
using a ridge vent.
[0020] FIG. 5 is a perspective partially sectioned view of the
thermal decking of FIG. 1 installed on a roof.
[0021] FIG. 6 is a schematic perspective view of a building roof
having the thermal decking of either FIG. 1 or FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] Referring to FIG. 1, thermal decking 100 comprises a first
panel 102 having an outside surface 104 and an inside surface 106
covered with a sheet or layer of foil 105. Foil 105 can be any
material that will sufficiently radiate heat but is preferably made
of metal and more preferably made of aluminum. Foil 105 will
generally be a poor radiator of heat but a good conductor of heat.
For example, the emissivity value of aluminum foil is roughly 3%
meaning that only 3% of the heat absorbed is given off in the form
of radiant heat. On the other hand, 97% is given off by conduction
through other materials in contact with the foil or by convection
currents. Foil 105 is attached to the inside surface 106 of the
first panel 102. By covering the wood with foil 105, the radiation
of heat from the wood is greatly reduced and only a small
percentage of heat conducted through the wood and onto foil 105 is
allowed to radiate into an air space.
[0023] All of the decking or panels disclosed herein can be made of
any material but is preferably made of wood and most preferable
plywood. Wood, especially plywood is used because the building
industry is familiar with using wood and plywood is a relatively
rigid insulating material that is commonly used as decking on a
roof. Also, it is relatively inexpensive, and because most
conventional decking is made of plywood, the present invention
could easily be installed on existing as well as new residential
and commercial buildings. The first panel 102 can vary in thickness
but is preferably about 1/2" thick 4' wide and 8' long. A second
panel 108 has an outside surface 110 and an inside surface 112 also
covered with foil 105. Inside surface 112 faces the foil covered
inside surface 106 of the first panel 102. The second panel 108 can
also vary in thickness but is preferably about 1/4" thick 4' wide
and 8' long or alternatively is about 1/2" thick 4' wide and 8'
long. At least one spacer 114 is positioned between the first panel
102 and the second panel 108. Spacer 114 can be any size and made
of any relatively rigid insulating material but is preferably made
of wood. Spacer 114 illustrated in FIG. 1 is preferably about 1"
thick, 2" wide, and can be any length so long as the spacer 114
creates a continuous chamber or air space 116. The air space 116
can be any thickness that would allow air to flow from an inlet 210
(FIG. 3) of the thermal decking 100 to an outlet 212 of the thermal
decking 100.
[0024] If more than one spacer 114 is used then the spacers 114 can
be evenly spaced across the first panel 102 and second panel 108.
The spacers 114 may be spaced apart about 16 inches to line up with
the ceiling joists, or spacers 114 may be spaced apart about 24
inches to line up with the rafters of the roof. Almost any desired
number of multiple spacers 114 can be used and the spacing between
each does not have to be equal or in any particular type of
pattern.
[0025] Air space 116 may be in the range of about 0.05 inch to
about 1 inch from the foil covered inside surface 106 of the first
panel 102 to the foil covered inside surface 112 of the second
panel 108 and is preferably approximately 3/4 inch. Air space 116
is a continuous conduit for the flow of air from inlet 210 to
outlet 212 of the thermal decking 100. Air space 116 must be open
or vented at opposite ends to allow an air current to flow through
air space 116 parallel to the lengths of spacers 114. The thickness
of approximately 3/4" has been determined to be optimal to avoid
eddies and static air spaces.
[0026] As seen in FIG. 1, thermal decking 100 has a single air
space 116 between each two spacers 114. When the thermal decking
100 is installed such that the first panel 102 is next to a heat
source, the heat from the heat source is conducted through the
outside surface 104 of the first panel 102 to the foil covered
inside surface 106 of the first panel 102. Foil 105 prevents most
of the heat from being radiated into the air space 116. However,
some of the heat is given off into the air space 116 in the form of
conduction by contact with convection currents. To dissipate the
heat in the convection currents to the outside surface a rotary air
handling device such as turbine 206 (FIG. 3) may be installed to
create the movement of air from inlet 210 to the outlet 212. This
eliminates most heat in the convection currents from being
conducted to the second panel 108 and then into the building. The
foil covered inside surface 112 of the second panel 108 reflects
any radiant heat back into the air space 116 and prevents the heat
from being radiated to the second panel 108 and then into the
building.
[0027] In a second embodiment shown in FIG. 2, a thermal decking
132 comprises a first panel 134 having an outside surface 136 and
an inside surface 128. First panel 134 can be any desired thickness
but is preferably about 1/2" thick 4' wide and 8' long. A second
panel 138 has an outside surface 140 and an inside surface 130 that
faces the inside surface 128 of the first panel 134. Inside
surfaces 128 and 130 optionally may be covered with foil 105. The
second panel 138 can also be of any desired thickness but is
preferably about 1/4" thick 4' wide and 8' long or alternatively is
about 1/2" thick 4' wide and 8' long. Positioned between the first
panel 134 and the second panel 138 is a radiant barrier 122. The
radiant barrier 122 is a panel with a top side 124 and a bottom
side 126 such that the top side 124 faces the inside surface 128 of
the first panel 134 and the bottom side 126 faces the inside
surface 130 of the second panel 138. Top side 124 and bottom side
126 are covered with foil 105. The radiant barrier 122 may have an
insulation material 150 sandwiched in between the top side 124 and
the bottom side 126. The insulation material 150 may be paper
material or some other thin material with insulating properties.
The insulation material 150 may also improve the handling and
instillation of the radiant barrier 122.
[0028] At least one upper spacer 142 is positioned between the
inside surface 128 of the first panel 134 and the top side 124 of
the radiant barrier 122. The upper spacer 142 can be any size and
is preferably about 1" thick, 2" wide, and can be any length so
long as a primary chamber or air space 144 is created. The
thickness of the air space 144 can be any thickness that would
allow air to flow from the entrance side 302 (FIG. 4) of the
thermal decking 132 to the exhaust side 304 of the thermal decking
132. If more than one upper spacer 142 is used, then the spacers
142 are spaced evenly across the first panel 134 and the radiant
barrier 122. The upper spacers 142 may be spaced apart about 16
inches to line up with the ceiling joists or spacers 142 may be
spaced apart about 24 inches to line up with the rafters. Almost
any number of multiple upper spacers 142 can be used and the
spacing between each of them does not have to be equal or in any
type of pattern. The primary air space 144 maybe in the range of
about 0.05 inch to about 1 inch and is preferably approximately 3/4
inch from the inside surface 128 of the first panel 134 to the top
side 124 of the radiant barrier 122. Approximately 3/4" has been
determined to be the optimal air space to avoid eddies and static
air spaces. Decking 132 has open opposite ends for air flow in air
spaces 144 parallel to spacers 142. The primary air space 144 is a
continuous conduit for the flow of air from an inlet 302 (FIG. 3)
of the thermal decking 132 to an outlet 304 of the thermal decking
132.
[0029] At least one lower spacer 146 is positioned between the
inside surface 130 of the second panel 138 and the bottom side 126
of the radiant barrier 122. Preferably, the lower spacer 146 is
directly below the upper spacer 142 however the spacers 142 and 146
may be in an alternating pattern or may be in a completely random
pattern. The lower spacer 146 can be any size but is preferably
about 1" thick, 2" wide, and can be any length so long as a
secondary chamber or air space 148 is created. The thickness of the
secondary air space 148 can be any thickness that would allow air
to flow from inlet 302 of the thermal decking 132 to the outlet 304
of the thermal decking 132. The secondary air space 148 may be in
the range of about 0.05 inch to about 1 inch and is preferably
approximately 3/4 inch from the inside surface 130 of the second
panel 138 to the bottom side 126 of the radiant barrier 122. The
opposite ends of secondary air space 148 are also open for air flow
in air space 148. The secondary air space 148 is a continuous
conduit for the flow of air from inlet 302 (FIG. 4) to outlet 304
and runs parallel with the primary air space 144.
[0030] When thermal decking 132 is installed such that the first
panel 134 is next to a heat source, the two air spaces 144 and 148
can greatly reduce heat from reaching the second panel 138 and
being transferred into the building. Heat from the heat source is
conducted through the first panel 134 and either radiated off foil
105 of the inside surface 128 of the first panel 134 and into air
space 144 or conducted due to convection currents in the primary
air space 144, where the heat is then dissipated due to the
movement of air from the entrance side 302 to the exhaust side 304.
The convection currents in air space 144 can conduct a small amount
of the heat to the top side 124 of radiant barrier 122. Foil 105 on
top side 124 may reflect the heat back into air space 144. Also,
some of the heat from the top side 124 of radiant barrier 122 may
conducted to the bottom side 126 of radiant barrier 122, where it
may be conducted to convection currents in the secondary air space
148. Foil 105 on inside surface 130 reflects heat back into air
space 148. The heat within air space 148 is then dissipated due to
the movement of air from the entrance side 302 (FIG. 4) to the
exhaust side 304 of thermal decking 132. Decking 132 greatly
reduces heat from reaching the second panel 138 and being radiated
into the building.
[0031] Thermal decking 100 or 132 may be installed on conventional
supporting structure such as roof rafters 208 (FIG. 3) in place of
the standard decking commonly used. Decking 100 is installed so
inlet 210 of the decking 100 is in communication with a soffit area
202 of a standard roof to allow for intake of air from the soffit
area 202, through inlet 210 and into the air space 116. Soffit area
202 is the conventional structure that encloses the edge portions
of the roof. Soffit area 202 has an opening 203 through incoming
air passes to inlet 210. Outlet 212 is an elongated opening
preferably located at the peak of the roof. Outlet 212 is
preferably a passageway extending along the peak of the roof, as
illustrated in FIG. 6. Outlet 212 is in communication with the
upper end of each air space 116 and vents to atmosphere. Outlet 212
may be open along its length to atmosphere, in which case, the air
may is moved solely by convection without any additional system to
facilitate the movement of the air. Alternately, if desired, a
rotary air moving device such as a wind driven or solar powered
turbine 206, electrically powered ridge vent 318 (FIG. 4), or
similar system for moving air may be installed at the peak of the
roof in communication with outlet 212 of thermal decking 100. The
turbine 206 draws air from the outlet 212 of the thermal decking
100 and releases it into the surroundings. As the turbine 206 draws
the air from outlet 212, a negative pressure in created in outlet
212 and air is drawn through the air space 116 towards outlet 212.
This creates a continuous air flow from the soffit area 202,
through inlet 210, into the air space 116, and out outlet 212.
[0032] At roof edge, the second panel 108 may be cut at least 0.5
inch shorter than the first panel 102, leaving a portion of the
first panel 102 extending past the second panel 108 to create inlet
210 for drawing air through the air space 116. Inlet 210 thus has a
width the same distance the distance between two of the spacers
114. The ceiling structure 211 of the building may be conventional
and preferably has conventional insulation located on it.
[0033] FIGS. 5 and 6 illustrate thermal decking 100 installed at a
hip joint of a roof. A central enclosed passageway 213 extends
upward along the ridge of the hip joint to exhaust passageway 212
located on the peak of the roof. Passageway 212 leads to an outlet,
which may have a turbine 206.
[0034] Referring to FIG. 4, thermal decking 132 could also be
installed on conventional roof rafters in much the same manner as
the thermal decking 100. If the thermal decking 132 is installed,
then the second panel 138 and the radiant barrier 122 on the inlet
side 302 may be cut at least 0.5 inch shorter than upper decking
136, leaving a portion of the first panel 134 extending past the
second panel 138 and the radiant barrier 122 to create inlet 301.
As in the first embodiment, inlet 302 is located in a soffit area
301 that has an opening 303 for air to flow in to inlet 302. A
ridge vent 304 may be installed at outlet 304 on the ridge or peak
of the roof to enhance air flow.
[0035] As shown in FIG. 4, thermal decking 100, or 132, could also
be installed on the wall studs in place of the standard sheathing
on side walls. The thermal decking 132 would be orientated such
that an inlet 316 is near the base or foundation of the house while
the outlet 318 is near the soffit area 202 of the house. Inlets 316
are in communication with air spaces 144, 148 of the thermal
decking 100 to create a natural draw to an outlet 318 and into
soffit 301. In soffit 301, the flow of air may continue from into
inlet 302 of the thermal decking 132 on the roof to outlet 304 at
the peak of the roof. A conventional brick veneer 213, such as
shown in FIG. 3, may be installed on the exterior of the wall
thermal decking 132 or 100.
[0036] An invention has been provided with several advantages. The
thermal decking of the present invention is simple in design and
economical to manufacture. It has improved insulation and heat
transfer characteristics for residential or industrial buildings.
The thermal decking does not have a dead air space wherein once the
air space is heated, the heat is conducted into the building. Also,
the present invention is more efficient and economical to use.
[0037] Although the device of the invention herein described is
intended primarily for use as decking on a roof, it should be
recognized that the thermal decking can be used on any surface that
needs superior insulating properties. While the foregoing
description basically describes the preferred embodiment of an
inventive device, it will be understood by those skilled in the art
that modifications embodied in various forms may be made without
departing from the spirit and scope of the invention as defined in
the following claims.
* * * * *