U.S. patent application number 12/118011 was filed with the patent office on 2009-11-12 for structural insulating panel and flat roof structure employing same.
This patent application is currently assigned to THERMAPAN STRUCTURAL INSULATING PANELS INC.. Invention is credited to Emil Taraba, Jeff Taraba.
Application Number | 20090277113 12/118011 |
Document ID | / |
Family ID | 40886956 |
Filed Date | 2009-11-12 |
United States Patent
Application |
20090277113 |
Kind Code |
A1 |
Taraba; Jeff ; et
al. |
November 12, 2009 |
Structural insulating panel and flat roof structure employing
same
Abstract
A structural insulating panel for use in a flat roof structure
comprises upper and lower structural layers and an intermediate
layer between the upper and lower structural layers. The
intermediate layer is shaped such that the upper structural layer
is sloped relative to a generally horizontal plane when the
structural insulating panel is installed in a flat roof
structure.
Inventors: |
Taraba; Jeff; (Fort Erie,
CA) ; Taraba; Emil; (Fort Erie, CA) |
Correspondence
Address: |
YOUNG BASILE
3001 WEST BIG BEAVER ROAD, SUITE 624
TROY
MI
48084
US
|
Assignee: |
THERMAPAN STRUCTURAL INSULATING
PANELS INC.
Fort Erie
CA
|
Family ID: |
40886956 |
Appl. No.: |
12/118011 |
Filed: |
May 9, 2008 |
Current U.S.
Class: |
52/302.1 ; 52/15;
52/408 |
Current CPC
Class: |
E04D 13/0481 20130101;
E04D 13/1693 20130101; E04D 3/352 20130101 |
Class at
Publication: |
52/302.1 ; 52/15;
52/408 |
International
Class: |
E04B 1/70 20060101
E04B001/70; E04D 13/04 20060101 E04D013/04; E04D 11/00 20060101
E04D011/00 |
Claims
1. A structural insulating panel for use in a flat roof structure
comprising: upper and lower structural layers; and an intermediate
layer between said upper and lower structural layers, said
intermediate layer being shaped such that said upper structural
layer is sloped relative to a generally horizontal plane when said
structural insulating panel is installed in a flat roof
structure.
2. A structural insulating panel according to claim 1 wherein said
intermediate layer is shaped such that the upper structural layer
is sloped in multiple dimensions relative to said horizontal
plane.
3. A structural insulating panel according to claim 2 wherein said
intermediate layer is shaped such that the upper structural layer
slopes generally linearly downwardly in two generally orthogonal
directions.
4. A structural insulating panel according to claim 2 Wherein said
intermediate layer is shaped such that the upper structural layer
curves downwardly in different directions.
5. A structural insulating panel according to claim 4 wherein an
upper surface of said intermediate layer on which said upper
structural layer is disposed, has a generally parabolic shape.
6. A structural insulating panel according to claim 1 wherein said
intermediate layer is shaped such that the upper structural layer
slopes generally linearly downwardly in a single direction.
7. A structural insulating panel according to claim 1 wherein said
intermediate layer is formed of foam material.
8. A structural insulating panel according to claim 1 wherein said
intermediate layer is sandwiched directly between said upper and
lower structural layers.
9. A structural insulating panel according to claim 9 wherein
thicknesses of said upper and lower structural layers are selected
to give said structural insulating panel a desired fire rating.
10. A structural insulating panel according to claim 9 wherein said
intermediate layer is shaped such that the upper structural layer
is sloped in multiple dimensions relative to said horizontal
plane.
11. A structural insulating panel according to claim 10 wherein
said intermediate layer is shaped such that the upper structural
layer slopes generally linearly downwardly in two generally
orthogonal directions.
12. A structural insulating panel according to claim 10 wherein
said intermediate layer is shaped such that the upper structural
layer curves downwardly in different directions.
13. A structural insulating panel according to claim 12 wherein an
upper surface of said intermediate layer on which said upper
structural layer is disposed, has a generally parabolic shape.
14. A structural insulating panel according to claim 9 wherein said
intermediate layer is shaped such that the upper structural layer
slopes generally linearly downwardly in a single direction.
15. A structural insulating panel according to claim 9 wherein said
intermediate layer is formed of foam material.
16. A structural insulating panel according to claim 15 wherein
said foam material is one of expanded polystyrene foam, urethane
foam, polyurethane foam and isocyanurate foam.
17. A structural insulating panel according to claims 9 wherein
said upper and lower structural layers are formed of material
selected from plywood, OSB, metal sheet or other suitable
material.
18. A structural insulating panel according to claim 1 wherein each
of said upper and lower structural layers has a thickness in the
range of from about 1/8'' to about 11/2'' and wherein said
intermediate layer had a minimum thickness of about 1'' and a
maximum thickness of about 16''.
19. A flat roof structure comprising: a plurality of abutting
structural insulating panels, each structural insulating panel
spanning at least a pair of adjacent rafters of said flat roof
structure and defining an upper decking surface on which roofing is
applied, said structural insulating panels being configured such
that said upper decking surface is non-horizontal thereby to
promote drainage.
20. A flat roof structure according to claim 19 wherein said
structural insulating panels are arranged at least one of
end-to-end and side-to-side.
21. A flat roof structure according to claim 20 wherein adjacent
structural insulating panels carry mating formations.
22. A flat roof structure according to claim 21 wherein said mating
formations are tongues and grooves.
23. A flat roof structure according to claim 20 further comprising
sealant to seal seams between adjacent structural insulating
panels.
24. A flat roof structure according to claim 20 wherein each
structural insulating panel comprises: upper and lower structural
layers; and an intermediate layer between said upper and lower
structural layers, said intermediate layer being shaped such that
said upper structural layer is sloped relative to a horizontal
plane.
25. A structural insulating panel according to claim 24 wherein
said intermediate layer is shaped such that the upper structural
layer is sloped in multiple dimensions.
26. A structural insulating panel according to claim 25 wherein
said intermediate layer is shaped such that the upper structural
layer slopes generally linearly downwardly in two generally
orthogonal different directions.
27. A structural insulating panel according to claim 25 wherein
said intermediate layer is shaped such that the upper structural
layer curves downwardly in different directions.
28. A structural insulating panel according to claim 24 wherein
said intermediate layer is shaped such that the upper structural
layer slopes generally linearly downwardly in a single
direction.
29. A structural insulating panel comprising: an intermediate layer
sandwiched between and adhered to first and second structural
layers, said intermediate layer varying in thickness such that said
first and second structural layers are non-parallel.
30. A structural insulating panel according to claim 29 wherein
said intermediate layer is formed of foam material.
31. A structural insulating panel according to claim 30 wherein
said foam material is one of expanded polystyrene foam, urethane
foam, polyurethane foam and isocyanurate foam.
32. A structural insulating panel according to claims 29 wherein
said upper and lower structural layers are formed of material
selected from plywood, OSB, metal sheet or other suitable
material.
33. A structural insulating panel according to claim 29 wherein
each of said upper and lower structural layers has a thickness in
the range of from about 1/8'' to about 11/8'' and wherein said
intermediate layer had a minimum thickness of about 1'' and a
maximum thickness of about 16''.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to building
structure and in particular, to a structural insulating panel and
flat roof structure employing the same.
BACKGROUND
[0002] Historically, flat or horizontal roofs on commercial and
residential buildings have been common in warmer, drier climates
where water accumulation as a result of precipitation is not a
problem. More recently, flat roofs have become popular in cooler,
wetter climates. Unlike sloped roofs, flat roofs have ineffective
drainage characteristics making them prone to leakage problems. In
wetter climates, to deal with this drainage issue, complex water
proofing is typically required in flat roofs. In commercial
buildings, drains are sometimes provided in the flat roofs to
collect rainwater and melting snow and direct the water off of the
roofs.
[0003] For example, U.S. Pat. No. 5,144,782 to Paquette et al.
discloses a draining system for water which may collect between the
upper and lower membranes of a flat insulated roof. Insulating
panels located between the upper and lower membranes are provided
at both their upper and lower faces with a network of intersecting
grooves. The networks of grooves communicate with each other
through passages made through the insulating panels or constituted
at the insulating panel joints. The grooves and passages provide
drainage channels for any water that has seeped under the upper
membrane as a result of perforations in the upper membrane. A lower
drain is sealed to and opens above the lower membrane to drain
water collected by the drainage channels. Drainage of the water
helps to prevent deterioration of the insulating panels and water
accumulation which may provoke overload problems.
[0004] Although such drainage structures are effective in removing
water from flat roofs, they add significant complexity to the
building structures and hence, increase costs making them
unsuitable in many environments. As will be appreciated,
alternative techniques to improve drainage in flat roofs are
desired.
[0005] It is therefore an object of the present invention at least
to provide a novel structural insulating panel and roof structure
employing the same.
SUMMARY
[0006] Accordingly, in one aspect there is provided a structural
insulating panel for use in a flat roof structure comprising upper
and lower structural layers and an intermediate layer between said
upper and lower structural layers, the intermediate layer being
shaped such that said upper structural layer is sloped relative to
a horizontal plane when said structural insulating panel is
installed in a flat roof structure.
[0007] In one embodiment, the intermediate layer is shaped such
that the upper structural layer is sloped in multiple dimensions
relative to the horizontal plane. The upper structural layer may
slope generally linearly downwardly in generally orthogonal
directions or may curve downwardly in different directions. In
another embodiment, the intermediate layer is shaped such that the
upper structural layer slopes generally linearly downwardly in a
single direction.
[0008] In one form, the intermediate layer is sandwiched directly
between the upper and lower structural layers. The thicknesses of
the upper and lower structural layers are selected to give the
structural insulating panel a desired fire rating. Each of the
upper and lower structural layers may have a thickness in the range
from about 1/8'' to about 11/8''. The intermediate layer may have a
minimum thickness of about 1'' and a maximum thickness of about
16''.
[0009] According to another aspect there is provided a flat roof
structure comprising a plurality of abutting structural insulating
panels, each structural insulating panel spanning at least a pair
of adjacent rafters of the flat roof structure and defining an
upper decking surface on which roofing is applied, the structural
insulating panels being configured such that the upper decking
surface is non-horizontal thereby to promote drainage.
[0010] The structural insulating panels in one form are arranged at
least one of end-to-end and side-to-side with adjacent structural
panels carrying mating formations. Sealant seals seams between the
adjacent structural insulating panels.
[0011] According to yet another aspect there is provided a
structural insulating panel comprising an intermediate layer
sandwiched between and adhered to first and second structural
layers, the intermediate layer varying in thickness such that the
first and second structural layers are non-parallel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Embodiments will now be described more fully with reference
to the accompanying drawings in which:
[0013] FIG. 1 is a top plan view of a flat roof structure employing
structural insulating panels;
[0014] FIG. 2 is a side elevational view of the roof structure of
FIG. 1;
[0015] FIG. 3 is an enlarged portion of FIG. 2;
[0016] FIG. 4 is a perspective view of a structural insulating
panel forming part of the flat roof structures of FIG. 1;
[0017] FIG. 5 is a cross-sectional view of FIG. 4 taken along line
5-5;
[0018] FIG. 6 is a cross-sectional view of FIG. 4 taken along line
6-6;
[0019] FIG. 7 is a top plan view of an alternative structural
insulating panel for use in a flat roof structure;
[0020] FIG. 8 is a cross-sectional view of FIG. 7 taken along line
8-8;
[0021] FIG. 9 is a cross-sectional view of FIG. 7 taken along line
9-9;
[0022] FIG. 10 is a top plan view of yet another structural
insulating panel for use in a flat roof structure;
[0023] FIG. 11 is a cross-sectional view of FIG. 10 taken along
line 11-11;
[0024] FIG. 12 is a cross-sectional view of FIG. 10 taken along
line 12-12;
[0025] FIG. 13 is an enlarged side elevational view of a portion of
adjacent structural insulating panels showing an alternative joint;
and
[0026] FIG. 14 is an enlarged side elevational view of a portion of
adjacent structural insulating panels showing yet another
joint.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0027] Turning now to FIGS. 1 to 3, a flat roof structure is shown
and is generally identified by reference numeral 30. The flat roof
structure 30 comprises a plurality of abutting structural
insulating panels 32 arranged in an array. In this embodiment, the
array comprises six (6) rows and three (3) columns of panels 32.
Those of skill in the art will appreciate that the 6.times.3 array
of panels 32 is shown for illustrative purposes only. The
dimensions of the panel array can vary significantly depending on
the overall size of the flat roof structure 30 and the dimensions
of the individual panels 32 in the array. The longitudinal
dimension of each panel 32 is selected so that each structural
insulating panel 32 spans at least one pair of adjacent rafters 34.
Typically, each structural insulating panel 32 will have a
lengthwise dimension in the range of from about eight (8) feet to
about twenty (20) feet and a widthwise dimension equal to about
four (4) feet. Suitable fasteners (not shown) such as screws or
nails are used to secure the structural insulating panels 32 to the
rafters 34.
[0028] The upper surfaces 36 of the structural insulating panels 32
define the decking 38 of the flat roof structure 30 on which
roofing (not shown) is applied. The structural insulating panels 32
are configured so that the decking 38 is pitched in multiple
dimensions thereby to promote drainage towards the outer peripheral
edges of the flat roof structure 30. The pitch in each dimension is
typically selected so that it does not exceed 1/12''. In the
embodiment of FIG. 1, the structural insulating panels 32 in column
C1, rows R1 to R3 and in column C3, rows R1 to R3 are configured so
that the flat roof structure 30 slopes linearly downwardly to the
right as indicated by arrows 40 and slopes linearly downwardly from
its central longitudinal axis 42 towards its peripheral side edge
44 as indicated by arrows 46. The structural insulating panels 32
in column C1, rows R4 to R6 and in column C3, rows R4 to R6 are
configured so that the flat roof structure 30 slopes linearly
downwardly to the right as indicated by arrows 40 and slopes
linearly downwardly from its longitudinal axis 42 towards its
peripheral side edge 48 as indicated by arrows 50. The structural
insulating panels 32 in column C2, rows R1 to R3 are configured so
that the flat roof structure 30 slopes linearly downwardly to the
left as indicated by arrow 52 and slopes linearly downwardly from
its longitudinal axis 42 towards its peripheral side edge 44 as
indicated by arrow 46. The structural insulating panels 32 in
column C2, rows R4 to R6 are configured so that the flat roof
structure 30 slopes linearly downwardly to the left as indicated by
arrow 52 and slopes linearly downwardly from its longitudinal axis
42 towards its peripheral side edge 48 as indicated by arrow
50.
[0029] Turning now to FIGS. 4 to 6, one of structural insulating
panels 32 is better illustrated. As can be seen, structural
insulating panel 32 comprises an intermediate layer 60 sandwiched
between and bonded to upper and lower structural layers 62 and 64
respectively by suitable adhesive. In this embodiment, the
intermediate layer 60 is formed of expanded polystyrene (EPS) foam
and comprises a core 70 typically having a thickness in the range
of from about 1'' to about 16'', a top skin 72 on the core 70
having a thickness of about 7/16'' and a bottom skin 74 on the core
70 having a thickness of about 5/8''. The upper and lower
structural layers 62 and 64 are formed of a suitable structural
material such as for example plywood and have a thickness generally
in the range of from about 1/8'' to about 11/8''. The thicknesses
of upper and lower structural layers 62 and 64 are selected to give
the flat roof structure 30 its desired fire rating.
[0030] The core 70 varies in thickness to give the structural
insulating panel 32 its desired pitch. As a result, the upper
structural layer 62 which overlies the top skin 72 of the
intermediate layer 60 conforms to the orientation of the
intermediate layer and thus, provides the sloped upper decking
surface onto which the roofing is applied. One side edge of the
lower structural layer 64 has a groove 80 formed therein and the
opposite side edge of the lower structural layer 64 has a tongue 82
formed thereon. The groove 80 is shaped to receive a tongue formed
on an adjacent structural insulating panel 32 and the tongue 82 is
shaped to be inserted into the groove formed in another adjacent
structural insulating panel 32.
[0031] Looking back to FIG. 3, one of the seams 90 between two
adjacent structural insulating panels 32 is shown. As can be seen,
the tongue 82 on the lower structural layer 64 of one structural
insulating panel is received in the groove 80 formed in the lower
structural layer 64 of the other structural insulating panel.
Adhesive caulking 92 is applied to the tongue 82 and/or groove 80
prior to insertion of the tongue into the groove to secure the
lower structural layers of the adjacent structural insulating
panels 32 together. A sealant 94 such as for example, a foam seal
or sill seal gasket, is used to fill any gaps between the
intermediate layers 60 and upper structural layers 62 of the
adjacent structural insulating panels at the seam 90.
[0032] In the above embodiment, the structural insulating panels 32
of the flat roof structure 30 are configured so that the flat roof
structure 30 slopes linearly downward in two different directions.
Those of skill in the art will appreciate however, that other
structural insulating panel configurations can be used in flat roof
structures 30 to promote drainage. For example, turning now to
FIGS. 7 to 9, another embodiment of a structural insulating panel
for use in a flat roof structure is shown and is generally
identified by reference numeral 132. Similar to the structural
insulating panel 32, structural insulating panel 132 also comprises
an intermediate EPS layer 160 sandwiched between upper and lower
structural layers 162 and 164 respectively. In this embodiment,
rather than sloping linearly downwardly in two different
directions, the core 170 of the intermediate layer 160 has a
parabolic shape and thus, curves downwardly from its center in all
directions towards the edges of the intermediate layer.
[0033] FIGS. 10 to 12 show yet another embodiment of a structural
insulating panel 232 for use in a flat roof structure. Similar to
the structural insulating panels 32 and 132, structural insulating
panel 232 comprises an intermediate EPS layer 260 sandwiched
between upper and lower structural layers 262 and 264 respectively.
In this embodiment, the core 270 of the intermediate layer 260
slopes linearly downwardly in only one direction.
[0034] Although the embodiments described and shown above show
adjacent structural insulating panels 32 as comprising mating
formations in the form of tongues and grooves, those of skill in
the art will appreciate that alternative joints between adjacent
structural insulating panels can be used. For example, FIG. 13
shows adjacent structural insulating panels 32 interconnected via
an overlap joint and FIG. 14 shows adjacent structural insulting
panels interconnected via a butt spline joint.
[0035] Although dimensions for the structural insulating panels and
components therefor, are provided above, those of skill in the art
will appreciate that the dimensional information is exemplary.
Depending on the environment in which the structural insulating
panels are being deployed, the overall dimensions of the structural
insulating panels and the dimensions of the panel components may
vary from those discussed above.
[0036] In the embodiments described above, the upper and lower
structural layers 62 and 64 are described as being formed of
plywood. Those of skill in the art will appreciate that the upper
and lower structural layers may be formed of other suitable
structural material such as for example OSB, metal sheet, fire
resistant board etc. Also, the intermediate layer 60 need not be
formed of EPS. Other foam material such as for example urethane
foam, polyurethane foam, isocyanurate foam etc. or other suitable
non-foam material such as for example honeycomb board may be
used.
[0037] While particular examples of structural insulating panels
that provide pitched upper decking surfaces are described and
illustrated above, those of skill in the art will appreciate that
the structural insulating panels may take on other orientations to
promote drainage. Of course, if desired the structural insulating
panels can be used on wall structures for structural and/or
decorative purposes.
[0038] Although embodiments have been described above with
reference to the drawings, those of skill in the art will
appreciate that variations and modifications may be made without
departing from the spirit and scope thereof as defined by the
appended claims.
* * * * *