U.S. patent application number 11/317245 was filed with the patent office on 2006-10-19 for vented insulation panel with reflecting surface.
This patent application is currently assigned to Atlas Roofing Corporation. Invention is credited to Robert H. Blanpied, Richard C. Roe.
Application Number | 20060230707 11/317245 |
Document ID | / |
Family ID | 37107115 |
Filed Date | 2006-10-19 |
United States Patent
Application |
20060230707 |
Kind Code |
A1 |
Roe; Richard C. ; et
al. |
October 19, 2006 |
Vented insulation panel with reflecting surface
Abstract
A thermally insulative building construction panel (10) is
comprised of a first or top sheet (20) that is a rigid
nail-anchoring material; a second sheet (22) comprised of aluminum
foil firmly adhered to the top sheet (20); and, a third or bottom
sheet (26) comprised of an insulation material comprising low
density foam insulation. A plurality of spacer members (24) are
sandwiched in fixed positions between the second sheet (22) and the
third (bottom) sheet (26) for defining air channels (25) between
the sheets and between the spacer members themselves to permit
multi-dimensional air flow substantially throughout the panel. In a
first example embodiment, plural discrete spacer members are
arranged in a pattern such that, for the discrete spacer members
arranged in any direction of alignment, an air channel extends
perpendicular to the direction of alignment. In a second example
embodiment, elongated plural spacer members are configured to
permit multi-dimensional air flow substantially throughout the
panel by having a surface thereof formed in a square wave shape
with alternating crests and troughs which essentially repeat along
a major dimension of the spacer member. In a third example
embodiment, panels of either the first example embodiment or the
second example embodiment have their first sheet formed with a
smaller surface area than the third sheet to facilitate formation
of an expansion gap between adjacent panels.
Inventors: |
Roe; Richard C.; (Marietta,
GA) ; Blanpied; Robert H.; (Swanee, GA) |
Correspondence
Address: |
NIXON & VANDERHYE, PC
901 NORTH GLEBE ROAD, 11TH FLOOR
ARLINGTON
VA
22203
US
|
Assignee: |
Atlas Roofing Corporation
Meridian
MS
|
Family ID: |
37107115 |
Appl. No.: |
11/317245 |
Filed: |
December 27, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60638513 |
Dec 27, 2004 |
|
|
|
Current U.S.
Class: |
52/794.1 |
Current CPC
Class: |
E04D 13/172 20130101;
E04D 13/1618 20130101 |
Class at
Publication: |
052/794.1 |
International
Class: |
E04C 2/34 20060101
E04C002/34 |
Claims
1. A thermally insulative building construction panel comprising: a
first sheet comprising a rigid nail-anchoring material; a second
sheet comprising a layer of aluminum foil that is securely adhered
to the first sheet; a third sheet comprising an insulation
material; plural discrete spacer members connected in fixed
positions between the second sheet and the third sheet for defining
air channels between the sheets and between the spacer members
themselves, the plural discrete spacer members being arranged in a
pattern to permit multi-dimensional air flow substantially
throughout the panel, the pattern being such that, for the discrete
spacer members arranged in an any direction of alignment, an air
channel extends perpendicular to the direction of alignment.
2. The panel of claim 1, wherein the layer of aluminum foil has a
shiny surface which faces toward the air channels.
3. The panel of claim 1, wherein the first sheet has a density in
excess of 25 pounds/cubic foot and the third sheet has a density
less than 5 pounds/cubic foot and having an insulative "R" value in
excess of 3.0 per inch thickness.
4. The panel of claim 1, wherein the first sheet comprises of a
material selected from the group consisting of plywood, Waferboard,
oriented strand board, and particle board.
5. The panel of claim 1, wherein the second sheet is uniformly
adhered to the top sheet.
6. The panel of claim 1, wherein the third sheet is comprised of an
insulation material selected from the group consisting of
polyurethane modified polyisocyanurate foam, polyurethane foam,
phenolic-formaldehyde foam, and polystyrene foam.
7. The panel of claim 1, wherein the spacer members are comprised
of at least one material selected from the group consisting of
solid wood, the materials of claim 2, the materials of claim 4, and
a prefabricated metal material.
8. The panel of claim 1, wherein the spacer members are at least
one-inch thick.
9. The panel of claim 1, wherein the spacer members are arranged in
a rectangular matrix.
10. The panel of claim 1, wherein the spacer members are set back
from along one or more edges of the panel.
11. The panel of claim 1, wherein the first sheet has a smaller
surface area than the third sheet to facilitate formation of an
expansion gap between adjacent panels.
12. A thermally insulative building construction panel comprising:
a first sheet comprising a rigid nail-anchoring material; a second
sheet comprising a layer of aluminum foil that is securely adhered
to the first sheet; a third sheet comprising an insulation
material; plural spacer members connected in fixed positions
between the second sheet and the third sheet for defining air
channels between the sheets and between the spacer members
themselves, the plural spacer members being configured to permit
multi-dimensional air flow substantially throughout the panel, the
plural spacer members having a surface thereof formed in a square
wave shape with alternating crests and troughs which essentially
repeat along a major dimension of the spacer member.
13. The panel of claim 12, wherein the first sheet has a density in
excess of 25 pounds/cubic foot and the third sheet has a density
less than 5 pounds/cubic foot and having an insulative "R" value in
excess of 3.0 per inch thickness.
14. The panel of claim 12, wherein the first sheet comprises of a
material selected from the group consisting of plywood, Waferboard,
oriented strand board, and particle board.
15. The panel of claim 12, wherein the second sheet is uniformly
adhered to the top sheet.
16. The panel of claim 12, wherein the third sheet is comprised of
an insulation material selected from the group consisting of
polyurethane modified polyisocyanurate foam, polyurethane foam,
phenolic-formaldehyde foam, and polystyrene foam.
17. The panel of claim 12, wherein the spacer members are comprised
of at least one material selected from the group consisting of
solid wood, the materials of claim 2, the materials of claim 4, and
a prefabricated metal material.
18. The panel of claim 12, wherein the spacer members are at least
one-inch thick.
19. The panel of claim 12, wherein the first sheet has a smaller
surface area than the third sheet to facilitate formation of an
expansion gap between adjacent panels.
20. The panel of claim 12, wherein each trough extends to a depth
of approximately one half the thickness of the spacer member to
define one of the air channels through the spacer member in a
length direction of the panel.
21. The panel of claim 12, wherein the crests and troughs have
essentially a same periodicity or length along a width dimension of
the panel, except for two extreme-most crests and troughs at each
end thereof.
22. The panel of claim 12, wherein the layer of aluminum foil has a
shiny surface which faces toward the air channels.
Description
BACKGROUND
[0001] This application claims the priority and benefit of U.S.
Provisional Patent Application 60/638,513, filed Dec. 27, 2004,
which is incorporated herein by reference in its entirety.
[0002] 1. Field of the Invention
[0003] The field of the invention pertains to building and
insulation panels used in building construction, and particularly
to structural panels used as support for the waterproofing
membranes, such as shingles, for roofing construction.
[0004] 2. Related Art and Other Considerations
[0005] Roofing membranes, including roofing shingles and other
forms of roofing cover, are widely used in the building
construction industry. The support panel underneath a roofing
membrane resides in one of the most destructive environments known
to the industry. Direct sunlight on the waterproofing membrane
creates temperatures in excess of 100.degree. F. many days during
the year. Both the membrane and the support panel must be
fabricated so they can endure this harsh and hostile environment.
At the same time, a high priority for the owners and/or residents
of the building covered by the membrane and support panel is a
comfortable environment indoors, and at the lowest possible cost.
The owners desire the lowest possible "up-front" cost as well as
the lowest possible daily operating costs. With these
considerations in mind, many roofing products have been proposed
and have had differing degrees of success and acceptability.
[0006] Oddly enough, an effective prefabricated thermal insulation
panel is inherently self-destructing. That is, in serving its
purpose of insulating a building for the purpose of conserving
energy, the panel stores high levels of heat. Such intense heat may
be deleterious to the panel structure per se. This heat build-up
problem is especially acute in the roofing environment. In the
roofmg environment, a dual panel assembly is often used as the
prefabricated thermal insulation panel. A dual-panel assembly
essentially comprises two parallel panels or sheets. The roofing
membrane is nailed or adhered to the upper of the two parallel
panels. The heat build-up problem is particularly severe in older
forms of dual-panel assemblies in which the high efficiency plastic
foam insulation panel is adhered directly to a member such as a
nailing-base panel.
[0007] A more recent example of a dual-panel assembly is
illustrated in U.S. Pat. No. 5,433,050, which is incorporated
herein by reference. The improved dual-panel assembly of U.S. Pat.
No. 5,433,050 separates the two panels by air channels that allow
air to pass between the top deck (also known as the nailing base)
and the underlying insulation board, thus causing a cooling effect
on all components. Embodiments of U. S. Pat. No. 5,433,050 as well
as a dual-panel assembly roofing product marketed by Atlas Roofing
Corporation as Vented-R Nail Base are particularly advantageous in
using, e.g., high R-Value spacer members to space the two panels
and thus form the air channels.
[0008] By contrast, inferior products utilize wooden "furring
strips" as the spacer strips. Such wooden furring strips are often
less than three inches wide, and thus may require as many as five
strips to be placed within a forty-eight inch length. When wood
furring strips are used as the spacer members to create the air
channels, the wood lowers the thermal resistance values (e.g.,
increases thermal conductance) of the insulative building panel
within the area where wood furring strips are used. In the winter
time in northern geographical regions, these areas may be seen on a
roof as strips of melted snow.
[0009] In more recent years, many products have been introduced
that utilize the special properties of aluminum. Highly polished
aluminum foil, or aluminum sheets, have the unique property of
reflecting up to ninety-seven-percent (97%) of the incoming radiant
energy. If it has been heated by conductance heat or convection
heat, that same aluminum will only radiate about three-percent (3%)
of the incident heat energy. This unique property of aluminum is
called "emissivity." Emissivity can be defined as the relative
ability of a surface to emit radiation, measured as the ratio of
the energy radiated by a surface to the energy radiated by a black
body at the same temperature.
[0010] It is known to adhere aluminum foil to a board known as
Oriented Strand Board (hereinafter, "OSB"). The primary use of
aluminum foil-adhered OSB is for roofing sheathing. In such use
generally manufacturers require the aluminum foil be installed
facing the open attic space. OSB products can also be used in
walls, facing either toward the interior or exterior. Two examples
of such products include LuminOX.RTM. (previously marketed by
Potlatch Corporation of Spokane, Wash., see, e.g.,
www.potlatchcorp.com). and "Solar Board" (produced by Norbord
Industries of Toronto, Canada).
[0011] In the earliest days when aluminum foil was promoted as a
viable insulation material, the promoters were largely unheard-of
companies, and the touted benefits tended to be in excess of actual
values. But that has all changed in recent years since governments
have taken a keen interest in building envelope insulation. For
example, the United States Department of Energy ("DOE") received
mandates to improve all energy-saving materials and systems. DOE
involvement provided impetus in energy research and building
insulation in particular. For example, the Oak Ridge National
Laboratories ("ORNL"), which is operated by the US DOE, has massive
amounts of information to help architects, engineers, and other
building construction professionals utilize energy-related facts.
See, for example, the fact sheet located at:
www.ornl.gov/roofs+walls/radiant/, which has eight sections
comprising a document with over a dozen pages of help and advice.
DOE also has an Office of Energy Efficiency and Renewable Energy
(EERE), which posts multiple web pages of extensive information on
radiant barrier insulation at EERE.gov.
[0012] Although a good radiant barrier does have some insulative
value, it may often be difficult to measure the actual "R-Value" of
a composite product which uses the radiant barrier in some
configurations.
[0013] It is therefore an object of the present invention to
provide a vented, insulative building panel that also utilizes the
special emissivity properties of aluminum and has good insulation
properties.
BRIEF SUMMARY
[0014] A multiple component panel assembly comprises a first sheet
of a rigid nail-anchoring material; a second sheet comprising a
layer of aluminum foil that is securely adhered to the first sheet;
and, a third sheet comprising an insulation material. Spacer
members are provided in a spacer layer between the second and third
sheets, the spacer members being configured to permit
multi-dimensional air flow substantially throughout the panel.
[0015] In a first example embodiment, plural discrete spacer
members are connected in fixed positions between the second sheet
and the third sheet for defining air channels between the sheets
and between the spacer members themselves. The plural discrete
spacer members are arranged in a pattern to permit the
multi-dimensional air flow substantially throughout the panel. The
pattern being such that, for the discrete spacer members arranged
in an any direction of alignment, an air channel extends
perpendicular to the direction of alignment.
[0016] In a second example embodiment, elongated plural spacer
members are configured to permit multi-dimensional air flow
substantially throughout the panel by having a surface thereof
formed in a square wave shape with alternating crests and troughs
which essentially repeat along a major dimension of the spacer
member. In a non-limiting example implementation, each trough
extends to a depth of approximately one half the thickness of the
spacer member to define one of the air channels through the spacer
member in a length direction of the panel. In an illustrated
example embodiment, the crests and troughs have essentially a same
periodicity or length along a width dimension of the panel, except
for two extreme-most crests and troughs at each end thereof.
[0017] In a third example embodiment, panels of either the first
example embodiment or the second example embodiment have their
first sheet formed with a smaller surface area than the third to
facilitate formation of a gap between adjacent panels.
[0018] In an illustrated implementation, the first sheet has a
density in excess of 25 pounds/cubic foot and the third sheet has a
a density less than 5 pounds/cubic foot and having an insulative
"R" value in excess of 3.0 per inch thickness. The first sheet
comprises of a material selected from the group consisting of
plywood, Waferboard, Oriented Strand Board (OSB), and particle
board. The third sheet is comprised of an insulation material
selected from the group consisting of polyurethane modified
polyisocyanurate foam, polyurethane foam, phenolic-formaldehyde
foam, and polystyrene foam. The spacer members are preferably
comprised of an insulation material, but can also be formed from
solid wood, the materials sutiable for the first sheet, or a
prefabricated metal material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a plan view of a radiant-vented nail base
insulation panel according to an example embodiment.
[0020] FIG. 2 is a side view of the radiant-vented insulation panel
of FIG. 1.
[0021] FIG. 3 is an end view of the radiant-vented insulation panel
of FIG. 1.
[0022] FIG. 4 is a sectioned side view of a spacer member which
comprises the panel of FIG. 1.
[0023] FIG. 5 is a plan view of a radiant-vented nail base
insulation panel according to another example embodiment.
[0024] FIG. 6 is a plan view of a radiant-vented nail base
insulation panel according to yet another example embodiment.
[0025] FIG. 7 is a plan view of a spacer member which comprises the
panel of FIG. 6.
[0026] FIG. 8 is a side view of the spacer member which comprises
the panel of FIG. 6.
[0027] FIG. 9 is an isometric view of the panel of FIG. 6.
[0028] FIG. 10A is a plan view of a radiant-vented nail base
insulation panel according to still another example embodiment;
FIG. 10B is a side view of two adjacent panels of the embodiment of
FIG. 10A shown from a length dimension; and FIG. 10C is a side view
of two adjacent panels of the embodiment of FIG. 10A shown from a
width dimension.
[0029] FIG. 11 is a partial perspective view, partially sectioned,
of a radiant-vented insulation panel of the embodiment of FIG. 1
installed on a sloped roof.
DETAILED DESCRIPTION
[0030] In the following description, for purposes of explanation
and not limitation, specific details are set forth such as
particular compositions, techniques, etc. in order to provide a
thorough understanding. However, it will be apparent to those
skilled in the art that the present invention may be practiced in
other embodiments that depart from these specific details. In other
instances, detailed descriptions of well-known substances and
methods are omitted so as not to obscure the description of the
present invention with unnecessary detail.
[0031] FIG. 1 and FIG. 2 show a prefabricated radiant-vented
insulation panel 10. The panel 10 comprises a first panel or sheet
20; a second panel or sheet 22, a plurality of spacer members 24;
and a third panel or sheet 26. The sheets 20, 22 and 26 lie in
parallel planes. While in one example implementation sheets 20 and
22 may lie in contacting relation, sheets 22 and 26 are maintained
in spaced-apart, parallel relationship by the spacer members 24.
Spacer members 24 are sandwiched in fixed positions between the
second sheet 22 and the third sheet 26 for defining air channels 25
between the sheets 22 and 26; the air channels 25 also extending
between the spacer members 24 themselves.
[0032] The first (or "top") sheet 20, also known as the nail-base
panel, is a strong, structural panel such as plywood, particle
board, Waferboard, or Oriented Strand Board ("OSB") that is capable
of holding nails or staples indefinitely. The second sheet 22 is in
all cases a layer of bright, shiny aluminum foil. The foil sheet 22
is firmly adhered to the nail-base panel 20. The third sheet 26 is
a board comprised of plastic foam insulation. The fourth component
of panel 10 is a layer of air channels 25 formed between the
aluminum foil 22 and the plastic foam insulation board 26. The air
channels 25 are created by strategically placed spacer members 24.
The spacer members 24 preferably permit air to circulate in all
directions.
[0033] As shown in FIG. 1, the panel 10 extends across a first
dimension as depicted by an arrow 28. In the illustrated
embodiment, the panel 10 extends approximately eight feet
(96-inches) across the dimension of arrow 28 (sometimes referred to
as the "length" dimension) and approximately four feet (48-inches)
across the dimension of arrow 30 (sometimes referred to as the
"width" dimension).
[0034] The spacer members 24 comprise a spacer layer wherein
plural, discrete spacer members 24 are arranged in a pattern which
permits air to travel both in a length direction and a width
direction in the spacer layer of panel 10. In other words, at least
one air channel 25 is provided for plural spacer members 24 aligned
in an any direction of alignment, the air channel 25 extending
perpendicular to the direction of alignment. As such, the spacer
members 24 with the air channels 25 provide multi-dimensional air
flow substantially throughout the panel 10.
[0035] In the illustrated example implementation of the FIG. 1
embodiment, the pattern of the discrete spacer members 24 is a
rectangular matrix having three rows and five columns. Each row of
discrete spacer members 24 extends along the dimension of arrow 28.
Each column extends along direction 30. For the spacer members 24
arranged in a row, e.g., the spacer members 24 extending along the
dimension of arrow 28, air channels 25 are provided orthogonally
(e.g., extending in the direction of arrow 30). Conversely, for the
spacer members 24 arranged in a column, e.g., the spacer members 24
extending along the dimension of arrow 30, air channels 25 aer
provided orthogonally (extending in the direction of arrow 28).
[0036] In the embodiment of FIG. 1, each spacer member 24 has an
essentially rectangular shape, with three of the rectangular spacer
members 24 situated in the interior of panel 10 having a full
spacer size (e.g., full size along both the length dimension and
the width dimension) and rectangular spacer members 24 situated
around the perimeter of panel 10 having a truncated spacer
size).
[0037] In some optional implementations, the spacer members which
are situated proximate or around the perimeter of the panel 10 can
have a spacer size that is essentially half size in a truncated
dimension. For example, the spacer members of the first row of
panel 10, e.g., those spacers situated at the top of panel 10 of
FIG. 1, can have half the width (in direction of arrow 30) as the
full spacers, so that juxtaposition of another panel 10 above the
illustrated panel would result in two half-width spacers being
juxtaposed in the width direction with a result that the two
juxtaposed spacers extend essentially the same extent along the
width direction of arrow 30 as would a single full size spacer.
[0038] While spacer members 24 of rectangular shape have been
illustrated, it will be appreciated that the spacer members 24 can
take other shapes, such a triangular, circular, or shapes having
more than four edges or sides.
[0039] As seen in FIG. 3 and FIG. 4, each spacer member 24 has a
thickness 32. As used herein, when referring to the panel 10 per se
or any component thereof, the term "thick" or "thickness" refers to
a dimension that is perpendicular to the plane in which arrows 28
and 30 lie. As depicted in FIG. 2, the overall composite panel 10
thickness 34 includes the sum of the thicknesses of sheets 20, 22,
26, and spacer members 24. The overall thickness 34 of the entire
composite panel 10 is not to be confused with the thickness 32 of
the spacer members 24. The spacer thickness 32 is typically used by
a customer when ordering product; whereas, the overall panel 10
thickness 34 is typically utilized by a building designer, loading
and shipping personnel, and contractors.
[0040] FIG. 3 shows the end view of the panel 10, where the length
(e.g., major dimension) of each spacer member 24 along the
dimension of arrow 30 can be seen. FIG. 4 is a side view of a
spacer member which comprises the panel of FIG. 1. FIG. 4 shows the
spacer thickness dimension 32, which is typically either 1-inch,
1.5-inches, or 2-inches. The thickness should be such as to
facilitate adequate air flow throughout the air channels 25.
[0041] Although the drawings of composite panel 10 of FIG. 1, FIG.
2, FIG. 3 and FIG. 4 are not to scale, these drawings do in other
respects depict an actual radiant-vented nail base insulation panel
according to one example embodiment. The number, location, size,
shape, and pattern of arrangement of the spacer material 24 are
variables as long as the supporting strength is adequate.
[0042] In the example embodiment of FIG. 4, the spacer members 24
are preferably comprised of pieces of polyisocyanurate foam board.
Polyisocyanurate foam board generally has two sheets of facer
material (e.g., "facers") which are adhered to and comprised of
polyisocyanurate foam core. The facers are preferably strongly
adhered to the core. In such embodiment, the rectangular spacer
pieces 24 can be up to 8-inches wide and over 12-inches long. In
other embodiments, the spacer members 24 can also be formed from
other insulation materials such as polyurethane foam,
phenolic-formaldehyde foam, and polystyrene foam; from solid wood;
from any one or more of the above-listed materials suitable for the
first sheet, or a prefabricated metal material.
[0043] FIG. 5 shows another embodiment of a radiant-vented nail
base insulation panel 10(5). In the embodiment of FIG. 5, wooden
strips 24(5) are used for the spacer members. Other layouts (e.g.,
patterns or arrangements of spacer pieces) also work well when
wooden strips are utilized, for which reason FIG. 5 is not meant to
be a restrictive design with wood spacers. In the particular
embodiment of FIG. 5, the wood pieces 24(5) are about 2-inches
wide, 6-inches long, and either 1-inch, 1.5-inches, or 2-inches
thick. The wooden spacers 24(5) are preferably equally spaced at
five (5) spacers across the forty-eight (48) inch width (e.g.,
across direction 30), leaving 1/8.sup.th-inch set-back at every
edge, and six (6) columns of 5 spacers per-row are equally spaced
along the ninety-six (96) inch length (e.g., along direction 28),
again leaving 1/8.sup.th-inch set-back at every edge. The set-back
allows for thermal expansion and contraction.
[0044] FIG. 5 thus depicts an aspect of the technology wherein
spacer members are set back or recessed from one or more edges of
vented nail base insulation panel assembly. The spacer members may
be recessed or set back along each edge of the entire perimeter as
shown in FIG. 5, or alternatively recessed from one or more (but
not all) selected edges of the panel.
[0045] FIG. 6 is a top view of a radiant-vented nail base
insulation panel 10(6) wherein specially prepared expanded
polystyrene (EPS) foam strips are used for spacer material 24(6).
FIG. 7 is a plan view of the specially prepared EPS foam strip
spacer member 24(6) for the panel 10(6) of FIG. 6. The EPS foam
strip spacer members 24(6) can be 4-inches wide in each spacer
location or 4-inches wide when used at the side edges of the
composite panel 10(6), or 6-inches wide when used as one of the
three (3) interior spacer members 24(6) of the composite panel
10(6).
[0046] FIG. 8 is a side view of the EPS foam strip spacer member
24(6) which comprises the panel 10(6) of FIG. 6. FIG. 6 and FIG. 8
show detailed dimensions of one example implementation. These
figures and dimensions are not meant in any way to be restrictive
or limiting, but only exemplary.
[0047] The EPS strips 24(6) have a surface thereof (either top or
bottom) configured with a square wave shape, and thereby having
alternating crests and troughs which essentially repeat along a
major dimension of each strip 24(6). The major dimension of each
strip 24(6) is parallel to dimension 30. Each trough extends to a
depth of approximately one half the thickness of the strip 24(6).
The crests and troughs have essentially a same periodicity or
length (e.g., 1 and 1/16 inch) along dimension 30, except for the
two extreme-most crests and troughs at each end of spacer 24(6),
which are shorter in length (e.g., about 1/2 inch).
[0048] FIG. 9 is an isometric view of panel 10(6) comprised of
venting strips 24(6) of FIG. 7 and FIG. 8. The panel 10(6) also
employs polyisocyanurate foam board as the bottom layer 26(6) and
OSB as the top layer 20. The top layer 20 is used to hold; e.g.,
shingles, for example, and (in the example implementation) can be
about 7/16'' thick.
[0049] The materials descriptions for the sheets or layers for any
embodiment described herein are also applicable for all other
embodiments and implementations described herein or encompassed
hereby.
[0050] FIG. 10A, FIG. 10B, and FIG. 10C illustrate a third example
embodiment of a panel 10(10) wherein the first sheet 20 (and second
sheet 22) are formed to have a smaller surface area than the third
sheet 26 (e.g., the insulation board) to facilitate formation of an
expansion gap G between adjacent panels (see two adjacent panels
10(10).sub.1 and 10(10).sub.2 in FIG. 10B and FIG. 10C). In the
particular implementation shown in FIG. 10, a bottom edge and left
edge of all three layers 20, 22, and 26 are aligned to be "square",
e.g., to have a square edge. However, in view of the slightly
smaller surface area or footprint of the first sheet 20 relative to
the third sheet 26, the first sheet 20 in recessed approximately
1/8 inch within the top and right edges of the third sheet 26 and
the remainder of panel 10(10). The recess of first sheet 20 in this
manner provides a slight off set or set back of first sheet 20
panel relative to third sheet 26 and the remainder of the panel.
This offset or undersizing of the first sheet 20 facilitates
formation of a desirable expansion gap G between adjacent panels.
In the particular implementation shown in FIG. 10A, FIG. 10B, and
FIG. 10C, the third sheet 26 has a length of eight feet in the
dimension of arrow 28 and a width of four feet in the dimension of
arrow 30, with the first sheet 20 and the second sheet 22 being
sized slightly smaller (e.g., 1/8 inch smaller in each
dimension).
[0051] It should be understood that more than two edges of the
panel could have offset or set back in the manner of FIG. 10A. For
example, as an alternative the offset or set back can occur around
the entire perimeter of the panel, if desired. Moreover, offset
amounts can vary depending on environmental or application issues
or manufacturer choice. Further, panels of either the first example
embodiment or the second example embodiment have their first sheet
formed with a smaller surface area than the third sheet to
facilitate formation of the expansion gap between adjacent panels
in the same or similar manner as illustrated or described with
reference to FIG. 10A-FIG. 10C.
[0052] FIG. 11 shows the prefabricated vented insulation panel 10
of the embodiment of FIG. 1 installed in a typical sloped roof
environment. While the panel of FIG. 1 is illustrated in FIG. 11,
FIG. 11 serves to illustrate generically the mounting of any of the
example embodiments described herein. The panel is illustrated as
being utilized on a building having vertical studs 40. The studs 40
support roof framing members, with the roof framing members in turn
supporting the panel 10. The roof framing members include rafters
42 for supporting under-decking 44. Top plates 46 are employed to
fasten the rafters 42 and joists 48 to the studs 40. The rafters 42
are tied together by the structural load-bearing under-decking
44.
[0053] Overlying the panel 10 is a conventional roofing membrane
system comprising a base sheet 50 overlaid with shingles 52, which
act as the waterproofing element on top. A vent cap 54 is provided
at the roof ridge. The function of the vent cap 54 is explained in
prior art publications, such as U.S. Pat. No. 4,852,314 to Moore,
which is incorporated herein by reference. A soffit side-fascia 56
is usually nailed to the ends of the rafters 42 and/or joists 48.
If an open-beam (e.g., Cathedral) ceiling design is utilized,
(i.e., no joists and no attic), the roof structural under-decking
44 becomes the ceiling. In this case, the space between the rafters
42 must be closed up with vertical wall structures, plus wall
plates, against the under-decking 44.
[0054] The first sheet 20, also known as the top deck, comprises a
rigid nail-anchoring material. The sheet 20 can be any ordinary
roofing deck material normally used as a nail base for roofing felt
and roofing shingles, such as plywood, Waferboard, Oriented Strand
Board (OSB), and particle board. First sheet 20 has a density in
excess of 25 lbs./cubic foot, and holds ordinary nail shanks. Some
high-density particleboard can be as high as 56 lbs./cubic foot,
but the typical nail base board density is 35-45 lbs./ft.sup.3. The
insulative value of sheet 20 is a maximum of R=1.25 per inch.
[0055] The preferred materials for the top sheet 20 are 7/16'' OSB,
1/2'' plywood, or 7/16'' Waferboard. The most preferred material is
OSB, as plywood often has concealed, interior voids.
[0056] The spacer members 24 have a generally elongated rectangular
shape and, as shown in FIG. 4, are of rectangular cross section.
The spacer members of the present invention can be made of any
normal building construction material that meets the requirements
of dimensions and compressive strength. In this regard, the
compressive strength of a spacer material is in excess of
20-pounds-per-square-inch ("psi"). Compressive strength as used
herein shall be defined as the amount of force (in psi) needed to
deform the material in the Z (vertical) direction by ten percent
(10%). The Z, or vertical direction, is that direction depicted in
FIG. 4 by the two arrows. The spacer members 24 can be made from a
metal material, such as a honeycomb structure made of thin aluminum
strips, as well as by other materials including those already
mentioned herein.
[0057] The second panel or sheet 22, also referred to as layer 22,
is highly polished aluminum foil. The aluminum foil can be any
caliper (thickness) and any hardness rating. The only requirement
is that the sheet be placed with the shiny, highly polished surface
facing away from the top layer 20, to which the aluminum foil 22 is
completely and firmly adhered. No foil spots (areas) should be left
loose from board 20.
[0058] The thickness of the aluminum foil sheet utilized to provide
radiated energy reflectance or low radiation energy emissivity is
not critical. However, the aluminum sheet should not be so thin
that "jobsite friction" will tear open a hole even if securely
adhered to the OSB (or other) nailing base board. For optimum cost,
the thickness of the aluminum foil should be as thin as possible
while still maintaining its integrity. The normal range of
thickness utilized to adhere to a strong nail base board is from
about 0.0003-inches up to about 0.0070-inches thick. Thinner foils
can and have been utilized with some measure of success and of
course thicker foils work very well, but increase the cost.
[0059] Since aluminum foils can be purchased with different
hardness ratings, the particular hardness used will depend more on
the properties needed to process the product during manufacturing
than upon the properties of the final product. In other words,
"Full Hard," "Half Hard," and "Full Soft" aluminum foil will all
work well in the final product, but will not perform the same in
any given manufacturing process.
[0060] When used properly, that is with the aluminum facing
generally down toward the flat ceiling, this foil prevents up to
97% of the heat energy coming into it from radiating down toward
the building's usable interior space. The shiny side of the foil
must be installed facing out, and is thereafter protected from foil
damage because an inherent advantage of this radiant cross-vented
nail base insulative building panel is that once assembled, the
aluminum foil is protected.
[0061] If the foil can be located next to a layer of quiet, or
slowly moving air about 3/4-inch thick, the resulting R-value can
be measured, and can be substantial; e.g. up to 2.7. Quiet, or
slowly moving air is always the best substance to have adjacent to
the polished aluminum. While the 3/4-inch thick air layer is
currently believed to be ideal, other layers, especially thicker
layers, will be more effective than any solid materials, such as
OSB. The location of the aluminum foil; e.g., what is next to it,
plays a role in how effective it is. For the radiant barrier to be
effective, it must face an air space. In other words, the layer of
aluminum foil has a shiny surface which faces toward the air
channels. The angle of the layer is also a variable. Horizontal is
better than vertical, and better than any other non-horizontal
angles.
[0062] The bottom sheet 26 is comprised of a structurally sound
plastic foam insulation material. For example, the bottom sheet 26
can be comprised of polyurethane modified polyisocyanurate foam,
polyurethane-foam, phenolic-formaldehyde foam, or polystyrene foam.
The polystyrene foam can be either the extruded type of foam board,
or the expanded type of foam board that is cut from a large block
into desired board thicknesses. The bottom sheet 26 preferably has
facers provided on both of its broad, flat surfaces. Inclusion of a
facer on the sheet 26 enhances application of a construction
adhesive to the sheet 26. If polystyrene sheets are used without a
protective skin (facer), the choice of construction adhesive is
limited to those without a strong organic solvent thinner.
[0063] The bottom layer 26 that is made from a structurally sound
plastic foam board has, at a 1-inch thickness, an insulative
"R-Value" above 3.0. An R-Value at a thickness of 1-inch is defined
as the RESISTANCE to thermal conductivity in units of: ( square
.times. .times. feet ) .times. ( degrees .times. .times. F . )
.times. ( hour ) ( British .times. .times. Thermal .times. .times.
Unit .times. [ BTU ] ) ##EQU1##
[0064] Most foam board insulation products used in building
construction are thicker than 1-inch; the average actually being
slightly over 2-inches. If a foam insulation board has an R-Value
of 6.0 at 1-inch, the same product at 2-inches has at least an
R-Value of double that; i.e., R=12.0 or higher. As an example,
Atlas Roofing Corporation's ACFoam.RTM.-II at 2.0-inches is
R=12.1.
[0065] In one embodiment, the spacer members 24 are secured in
place by a construction grade adhesive such as an adhesive of the
type known as a subfloor and deck adhesive. Contech's PL-400, H B
Fuller's "Sturdibond", and Macklenburg-Duncan's "MD 400" are
examples of appropriate construction grade adhesives when the foam
board 26 has facers and/or the spacers 24 are wood or foam board
with their own facers. In other embodiments, the spacer members 24
can be secured in place by hot melt gluing techniques, or by
mechanical fastening (including broad headed nails and/or staples).
It has further been discovered that if the processing is handled
carefully, the common white glue ("Elmer's" type) will fasten the
EPS vent strips of the preferred embodiment to both the aluminum
foil and felt-faced polyisocyanurate, or polystyrene, foam board
insulation 26. Care must be taken to not wiggle nor jiggle the
assembled radiant-vented nail base panels 10 while the white glue
slowly dries.
[0066] Thus the panels described herein provide a distinct
improvement over prior art ventilating and insulating panels. These
improved products allow the benefits of any prior art vented nail
base insulation panel product, and also add the measurable benefit
of providing a radiant barrier that has been recognized by the USA
Department Of Energy (DOE) as a valuable means of conserving
energy.
[0067] According to some of its aspects, a thermally insulative
building construction panel comprises: a first sheet, the first
sheet comprising a rigid nail-anchoring material having a density
in excess of 25 lbs./cubic foot; a second sheet, the second sheet
comprising a layer of aluminum foil that is securely adhered to the
first sheet; a third sheet, the third sheet comprising an
insulation material having a density less than 5 lbs./cubic foot
and having an insulative "R" value in excess of 3.0 per inch
thickness; and, a plurality of spacer members connected in fixed
positions between the second sheet and the third sheet for defining
air channels between the sheets and between the spacer members
themselves, the spacer members being (preferably directly)
connected to the second sheet and the third sheet for maintaining a
spaced parallel relationship between the second sheet and the third
sheet.
[0068] The top sheet, or rigid nail-anchoring material is
preferably comprised of a material selected from the group
consisting of plywood, Waferboard, oriented strand board, and
particle board. The second sheet is preferably uniformly adhered to
the top sheet and is comprised of aluminum foil. The third sheet,
or bottom sheet, is preferably comprised of an insulation material
selected from the group consisting of polyurethane modified
polyisocyanurate foam, polyurethane foam, phenolic-formaldehyde
foam, and polystyrene foam. The spacer members are comprised of at
least one material selected from the group consisting of solid
wood; plywood, Waferboard, oriented strand board, and particle
board; polyurethane modified polyisocyanurate foam, polyurethane
foam, phenolic-formaldehyde foam, and polystyrene foam; and a
prefabricated metal material. The spacer members are preferably at
least one-inch thick.
[0069] The structural support panel for the waterproofing membrane
as herein described also provides a high level of thermal
insulation, protecting the interior temperature from the wide
changes in outside temperatures, as well as protection from the
sun's radiant energy. In this regard, the small up-front charge for
aluminum foil adhered to the nail-base panel is expected to pay for
itself with lower heating or air conditioner costs.
[0070] Other advantages herein provided are provision of an
insulative building panel that (1) allows air to move in all
directions; (2) utilizes scrap plastic foam for spacer material,
thus improving the R-Value at the spacer locations and saving some
plastic waste from expensive land-fills; and (3) utilizes the
unique emissivity properties of aluminum.
[0071] Another substantial advantage of the embodiments herein
described and modifications thereof is that (4) the aluminum foil
is protected from damage caused by jobsite collisions during
handling and installation.
[0072] Two other advantages of the embodiments herein described and
modifications thereof are (5) the provision of an insulative
building panel which can reduce the number of spacer members
required along any given dimension; and, (6) the provision of an
insulation panel with better thermal resistance per equal thickness
when compared to prior art panels.
[0073] Yet another advantage of the embodiments herein described
and modifications thereof is (7) the ability to make insulative
building panels having an essentially unlimited range of
cross-ventilation in two dimensions while maintaining compressive
load and strength requirements.
[0074] While the invention has been described in connection with
what is presently considered to be the most practical and preferred
embodiment, it is to be understood that the invention is not to be
limited to the disclosed embodiment, but on the contrary, is
intended to cover various modifications and equivalent
arrangements.
* * * * *
References