U.S. patent application number 14/344808 was filed with the patent office on 2015-02-26 for composite construction panels and applications thereof.
This patent application is currently assigned to Phase Change Energy Solutions, inc.. The applicant listed for this patent is Ken Farrish, Peter F. Horwath, Byron Owens, Reyad I Sawafta, James D. Thornsberry. Invention is credited to Ken Farrish, Peter F. Horwath, Byron Owens, Reyad I Sawafta, James D. Thornsberry.
Application Number | 20150056404 14/344808 |
Document ID | / |
Family ID | 47018481 |
Filed Date | 2015-02-26 |
United States Patent
Application |
20150056404 |
Kind Code |
A1 |
Sawafta; Reyad I ; et
al. |
February 26, 2015 |
Composite Construction Panels And Applications Thereof
Abstract
In one aspect, composite construction materials are described
herein. In some embodiments, a composite construction panel
comprises a substrate layer, a cover layer separated from the
substrate layer by one or more spacers, and at least one mat
disposed between the substrate layer and the cover layer, wherein
the mat comprises at least one phase change material disposed in at
least one phase change region.
Inventors: |
Sawafta; Reyad I;
(Greensboro, NC) ; Farrish; Ken; (Greensboro,
NC) ; Owens; Byron; (Asheboro, NC) ; Horwath;
Peter F.; (New London, NC) ; Thornsberry; James
D.; (Meridian, MS) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Sawafta; Reyad I
Farrish; Ken
Owens; Byron
Horwath; Peter F.
Thornsberry; James D. |
Greensboro
Greensboro
Asheboro
New London
Meridian |
NC
NC
NC
NC
MS |
US
US
US
US
US |
|
|
Assignee: |
Phase Change Energy Solutions,
inc.
Greensboro
NC
|
Family ID: |
47018481 |
Appl. No.: |
14/344808 |
Filed: |
September 14, 2012 |
PCT Filed: |
September 14, 2012 |
PCT NO: |
PCT/US12/55500 |
371 Date: |
October 9, 2014 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61535932 |
Sep 16, 2011 |
|
|
|
Current U.S.
Class: |
428/106 ;
428/188; 428/212; 428/304.4; 428/422.8; 428/423.1; 428/457;
428/703; 428/98 |
Current CPC
Class: |
F28D 20/023 20130101;
Y10T 428/24066 20150115; Y10T 428/249953 20150401; E04C 2/08
20130101; A62C 2/065 20130101; A62C 35/10 20130101; E04C 2/205
20130101; Y10T 428/24 20150115; Y10T 428/31551 20150401; E04B 9/001
20130101; F28D 20/026 20130101; E04C 2/34 20130101; Y10T 428/31547
20150401; E04B 1/80 20130101; E04B 9/0457 20130101; E04C 2/292
20130101; E04C 2/523 20130101; Y10T 428/24744 20150115; Y02E 60/14
20130101; E04B 9/045 20130101; F28D 20/02 20130101; Y02E 60/145
20130101; Y10T 428/24942 20150115; E04C 2/521 20130101; B32B 3/08
20130101; Y10T 428/31678 20150401; B32B 3/085 20130101 |
Class at
Publication: |
428/106 ;
428/703; 428/457; 428/212; 428/188; 428/423.1; 428/422.8;
428/304.4; 428/98 |
International
Class: |
E04C 2/292 20060101
E04C002/292; E04B 1/80 20060101 E04B001/80; E04C 2/34 20060101
E04C002/34; E04C 2/52 20060101 E04C002/52; E04C 2/08 20060101
E04C002/08; E04C 2/20 20060101 E04C002/20 |
Claims
1. A composite construction panel comprising: a substrate layer; a
cover layer over the substrate layer and separated from the
substrate layer by one or more first spacers; and a plurality of
mats disposed between the substrate layer and the cover layer,
wherein the mats are vertically separated from one another in a
stacked configuration by one or more second spacers and comprise at
least one phase change material disposed in at least one phase
change region.
2. The panel of claim 1, wherein the plurality of mats comprises a
first mat comprising a first phase change material disposed in a
first phase change region and a second mat comprising a second
phase change material disposed in a second phase change region,
wherein the first and second phase change materials are differing
phase change materials and the first mat is vertically separated
above the second mat.
3. The panel of claim 2, wherein the first phase change material
has a transition temperature above about 30.degree. C. and the
second phase change material has a transition temperature below
about 30.degree. C.
4. A composite construction panel comprising: a substrate layer; a
cover layer over the substrate layer and separated from the
substrate layer by one or more spacers; and at least one mat
disposed between the substrate layer and the cover layer, wherein
the mat comprises a plurality of phase change regions arranged in a
plurality of rows, wherein a first row comprises a first phase
change material and a second row comprises a second phase change
material, the first and second phase change materials being
differing phase change materials.
5. The panel of claim 4, wherein the first and second phase change
materials have differing phase transition temperatures.
6. The panel of claim 5, wherein the first phase change material
has a transition temperature above about 30.degree. C. and the
second phase change material has a transition temperature below
about 30.degree. C.
7. The panel of claim 1, wherein one or both of the substrate layer
and the cover layer is formed from a foam.
8. The panel of claim 7, wherein the foam comprises polyurethane or
polyisocyanurate.
9. The panel of claim 7, wherein a fire retardant or extinguisher
is disposed in the foam.
10. The panel of claim 7, wherein a phase change material is
disposed in the foam.
11. The panel of claim 1, wherein one or both of the substrate
layer and the cover layer is formed from wood, plywood, particle
board, or oriented strand board.
12. The panel of claim 1, wherein one or both of the substrate
layer and the cover layer is formed from gypsum board.
13. The panel of claim 1, wherein one or both of the substrate
layer and the cover layer is formed from metal.
14. The panel of claim 1, wherein at least one spacer is
hollow.
15. The panel of claim 14, wherein a fire retardant or extinguisher
is disposed in the interior of the hollow spacer.
16. The panel of claim 14, wherein a phase change material is
disposed in the interior of the hollow spacer.
17. The panel of claim 16, wherein the phase change material
comprises one or more salt hydrates.
18. The panel of claim 1, wherein the spacers at least partially
define vent spaces, cross vent channels, or both.
19. The panel of claim 18, wherein the vent spaces and cross vent
channels are sealed.
20. The panel of claim 18, wherein the panel is coupled to one or
more fans operable to ventilate or provide air flow in the vent
spaces, cross vent channels, or both.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority pursuant to 35 U.S.C.
.sctn.119(e) to U.S. Provisional Patent Application Ser. No.
61/535,932, filed on Sep. 16, 2011, which is hereby incorporated by
reference in its entirety.
FIELD
[0002] The present invention relates to composite construction
panels and, in particular, to composite construction panels
comprising a phase change material (PCM).
BACKGROUND
[0003] In recent years latent heat storage has become increasingly
important in a wide array of technologies. Latent heat includes
thermal energy released or absorbed during a change of state of a
material without a substantial change in the temperature of the
material. The change of state can include a phase change such as a
solid-liquid, solid-gas, liquid-gas, or solid-solid phase
change.
[0004] Due to their latent heat storage properties, phase change
materials (PCMs) have found application in a wide array of thermal
energy technologies. However, the use of PCMs in building and
construction applications has been somewhat limited by
disadvantages associated with the phase transitions of some PCMs.
Improved building and construction materials including PCMs are
desired,
SUMMARY
[0005] In one aspect, composite construction panels are described
herein which, in some embodiments, may provide one or more
advantages over prior construction panels. For example, in some
embodiments, a composite construction panel described herein can be
used as an underlayment for a roofing membrane to lower the average
surface temperature and extend the useful lifetime of the membrane.
In other embodiments, a composite construction panel described
herein can be used as an underlayment for one or more solar panels,
thus extending the useful lifetime of the solar panels and helping
the solar panels maintain higher efficiency by operating at lower
average temperatures. Composite construction panels described
herein, in some embodiments, can also be used to construct
ceilings, walls, and/or roofs. Moreover, in some embodiments, a
composite construction panel described herein can help extinguish
or prevent fires.
[0006] In some embodiments, a composite construction panel
described herein comprises a substrate layer, a cover layer over
the substrate layer and separated from the substrate layer by one
or more spacers, and at least one mat disposed between the
substrate layer and the cover layer, wherein the mat comprises at
least one phase change material disposed in at least one phase
change region. A phase change region, in some embodiments,
comprises a pouch. Further, in some embodiments, the mat comprises
a plurality of phase change regions or pouches comprising a PCM. In
such embodiments, the phase change regions or pouches, if desired,
can be arranged in an array or grid pattern, such as an array of
equidistantly spaced, phase change regions or pouches. Further, in
some embodiments, at least one phase change region or pouch
protrudes above the mat.
[0007] In addition, in some embodiments, the spacers of a composite
construction panel described herein define one or more vent spaces
between the substrate layer and the cover layer of the panel.
Moreover, in some embodiments, cross vent channels are provided in
the vent spaces between adjacent phase change regions or
pouches.
[0008] In some embodiments, a composite construction panel
described herein comprises a plurality of mats disposed between the
substrate layer and the cover layer, wherein the mats are
vertically separated from one another in a stacked configuration by
one or more spacers and comprise at least one PCM disposed in at
least one phase change region or pouch. In some embodiments, the
plurality of mats comprises a first mat comprising a first PCM
disposed in a first phase change region and a second mat comprising
a second PCM disposed in a second phase change region, wherein the
first and second PCMs are differing PCMs. Differing PCMs, in some
embodiments, exhibit differing phase transition temperatures.
[0009] Moreover, in some embodiments, a mat of a composite
construction panel described herein comprises a plurality of phase
change regions arranged in a plurality of rows, wherein a first row
comprises a first PCM and a second row comprises a second PCM, the
first and second PCMs being differing PCMs. The differing PCMs, in
some embodiments, can exhibit differing phase transition
temperatures.
[0010] Further, in some embodiments of composite construction
panels described herein, one or both of the substrate layer and the
cover layer of the panel is formed from a foam such as a
polyurethane foam. Moreover, in some embodiments comprising a foam
substrate or cover layer, a fire retardant or extinguisher is
disposed in the foam. In other embodiments, a PCM is disposed in
the foam. In some embodiments, one or both of the substrate layer
and the cover layer is formed from wood, plywood, particle board,
oriented strand board, gypsum board, or metal.
[0011] In addition, in some embodiments, a spacer of a composite
construction panel is hollow. Further, in some embodiments, a fire
retardant or extinguisher is disposed in the interior of the hollow
spacer. In other embodiments, a PCM is disposed in the interior of
the hollow spacer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The foregoing and other objects, features, and advantages of
the invention will be apparent from the following more particular
description of preferred embodiments as illustrated in the
accompanying drawings in which reference characters refer to the
same parts throughout the various views. The drawings are not
necessarily to scale, emphasis instead being placed upon
illustrating the principles of the invention.
[0013] FIG. 1A is a top view of a composite panel according to a
first example embodiment;
[0014] FIG. 1B is a sectioned side view of the composite panel of
FIG. 1A taken along line 1B-1B;
[0015] FIG. 1C is a sectioned side view of the composite panel of
FIG. 1B taken along line 1C-1C.
[0016] FIG. 2A is a top view of a composite panel according to a
second example embodiment;
[0017] FIG. 2B is a sectioned side view of the composite panel of
FIG. 2A taken along line 2B-2B;
[0018] FIG. 2C is a sectioned side view of the composite panel of
FIG. 2B taken along line 2C-2C.
[0019] FIG. 3 is a sectioned side view of a composite panel
according to a third example embodiment.
[0020] FIG. 4 is a sectioned side view of a composite panel
according to a fourth example embodiment.
[0021] FIG. 5 is a sectioned side view of a composite panel
according to a fifth example embodiment.
[0022] FIG. 6 is a flowchart showing example acts of steps included
in an example method of fabricating certain embodiments of
composite construction panels described herein.
[0023] FIG. 7 is a sectioned side view of a composite panel
according to another example embodiment.
[0024] FIG. 8 is a sectioned side view showing an energy-harnessing
assembly which comprises an energy-harnessing body mounted on or
integrally formed with a composite construction panel according to
any of the embodiments described herein.
[0025] FIG. 9 is a sectioned side view of a composite panel
according to another example embodiment.
[0026] FIG. 10 is a top view of a composite panel according to
another example embodiment.
DETAILED. DESCRIPTION
[0027] In the following description, for purposes of explanation
and not limitation, specific details are set forth such as
particular architectures, interfaces, techniques, etc. in order to
provide a thorough understanding of the present invention. 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. That is, those skilled in the art will be
able to devise various arrangements which, although not explicitly
described or shown herein, embody the principles of the invention
and are included within its spirit and scope. In some instances,
detailed descriptions of well-known devices and methods are omitted
so as not to obscure the description of the present invention with
unnecessary detail. All statements herein reciting principles,
aspects, and embodiments of the invention, as well as specific
examples thereof, are intended to encompass both structural and
functional equivalents thereof. Additionally, it is intended that
such equivalents include both currently known equivalents as well
as equivalents developed in the future, i.e., any elements
developed that perform the same function, regardless of
structure.
[0028] The technology disclosed herein concerns composite
construction panels which incorporate a phase change material
(PCM), methods of making the same, and products which utilize or
incorporate the same. Such products may include, for example, solar
cell units and photovoltaic cell units.
[0029] FIG. 1A, FIG. 1B, and FIG. 1C illustrate a first example
embodiment of a composite construction panel 20 which comprises a
mat or panel 22 which includes a phase change material and thus
provides phase change properties. For sake of simplicity, such mat
or panel comprising a phase change material and providing phase
change properties is herein referred to as the "phase change mat".
FIG. 1A, FIG. 1B, and FIG. 1C show top, side, and end views,
respectively, of the composite construction panel 20 of the first
example embodiment.
[0030] In the composite construction panel 20 the phase change mat
22 serves as one component layer of the multi-layer composite
panel. Other component layers of composite construction panel 20
include substrate layer 26; cover layer 28; and insulation layer
30. In addition, composite construction panel 20 includes two or
more spacers 32 which serve to at least partially define or at
least partially border one or more vent spaces 34. As explained
herein, in differing embodiments the materials comprising substrate
layer 26, cover layer 28, insulation layer 30, and spacers 32 can
vary, and additional layers can also be added.
[0031] In the example embodiment of FIG. 1A, FIG. 1B, and FIG. 1C,
as in some other example embodiments described herein, the
composite construction panel comprises two end spacers 32 and an
intermediate spacer situated approximately equidistant between the
two end spacers 32. It should be appreciated that, depending on
size of the composite construction panel and structural integrity
factors, two, three, or more spacers 32 may be provided. The
spacers 32 divide or partition a portion of the interior of the
composite construction panel into the vent spaces 34.
[0032] In an example embodiment, the phase change mat 22 comprises
regions of phase change material, also known as phase change
regions 40, and sometimes referred to as "pouches". Preferably the
regions are discrete regions which extend or protrude from a plane
of the base of phase change mat 22. In the example implementation,
phase change regions 40 have an outer cover which may comprise the
same materials as does the base of phase change mat 22, with the
cover defining a pocket or cavity in which phase change material 44
resides. The phase change material 44 in the phase change regions
40 is thus "encapsulated," and preferably (even in a liquid state)
has an extremely high viscosity and would not `leach out` if
fasteners for another board (e.g., a re-roof cover board) were to
penetrate the phase change material 44. Description of the phase
change material 44 is provided subsequently herein.
[0033] In the example embodiment of FIG. 1A, FIG. 1B, and FIG. 1C,
as in certain other but not all embodiments hereof, the phase
change regions 40 of phase change mat 22 extend or protrude above
the plane of the base of phase change mat 22 and thus extend or
protrude into the vent spaces 34 of the composite construction
panel. In the example embodiment of FIG. 1A, FIG. 1B, and FIG. 1C,
such phase change regions 40 have the shape or configuration of
essentially square blocks or pouches. FIG. 1A thus illustrates the
composite construction panel 20 as comprising one or more arrays of
essentially equidistantly spaced, square phase change regions 40.
Cross vent channels 46 are provided in vent spaces 34 between
adjacent phase change regions 40.
[0034] FIG. 1A, like top views of other embodiments, shows the
footprint of the composite construction panel. Dimensions of the
composite construction panel may vary in different embodiments, so
that the footprint dimensions per se are not critical. The
footprint dimensions may be four feet width by four feet length, or
four feet width by eight feet length, in two example
implementations. The footprint dimensions, and thus the internal
arrangement (number of phase change regions 40 and spacers 32), may
be dependent upon environment or nature of use or application.
Other dimensions are also possible. Any dimensions not inconsistent
with the objectives of the present invention may be used.
[0035] FIG. 1B, like other side views, shows a thickness of the
composite construction panel. In example embodiments, a thickness
of substrate layer 26 is one inch; a thickness of the spacers 32 is
one inch; a thickness of insulation layer 30 is two inches; and a
thickness of cover layer 28 is one-half inch. In an example
implementation, the spacers 32 have a length of four inches along
the side dimension (as shown across the sheet of FIG. 1B). Other
dimensions are also possible. Any dimensions not inconsistent with
the objectives of the present invention may be used.
[0036] In one example embodiment, both substrate layer 26 and
insulation layer 30 are insulation layers, the R-value of
insulation layer 30 preferably being twice that of substrate layer
26. In other words, the insulation layer (e.g., a foam board) which
serves as insulation layer 30 and which covers the vent spaces 34
and phase change mat 22 has twice the R-value as substrate layer 26
(which may be a foam board on the bottom surface of the composite).
This 2:1 R-value ratio is believed to represent an optimum heat
transfer mechanism, as the higher R-value board on the top will
provide the right amount of insulation from the radiant energy of
the `hot side` from reaching the phase change materials, whereas
the lower R-value on the bottom of the panel delays heat transfer
from the `cold side` and will allow the phase change materials to
change back to the lower temperature (e.g., solid) phase during
cooler time periods (e.g., at night) thus eliminating the peak heat
load daily cycling that occurs with conventional insulation.
[0037] In one example embodiment, cover layer 28 comprises oriented
strand board (OSB); substrate layer 26 comprises a closed-cell
polyiso (e.g., polyisocyanurate) foam board (such as that marketed
by Atlas Roofing Corporation as ACFoam-III.RTM.); and insulation
layer 30 comprises a polyiso sheathing (such as that marketed by
Atlas Roofing Corporation as Energy Shield.RTM.). The insulation
layer 30 preferably has non-reflective trilaminate facers
(foil-kraft-foil) on one side and a trilaminate or solid foil facer
on an unprinted back side. It will be appreciated that the
composition of the aforementioned layers can vary in differing
embodiments.
[0038] FIG. 2A, FIG. 2B, and FIG. 2C illustrate a second example
embodiment of a composite construction panel 20(2). The second
example embodiment differs from the first example embodiment
primarily in the shape of the phase change regions. Whereas in the
first example embodiment the phase change regions have an
essentially square shape, in the second example embodiment the
phase change regions 40(2) have an essentially rectangular shape. A
major dimension of the phase change regions 40(2) may extend
essentially along the entire width of the composite construction
panel 20(2) as shown, or only along a portion thereof. Moreover,
one or more essentially rectangular phase change regions 40(2) may
be aligned across the width dimension so that vent channels may be
provided between minor dimensions of adjacent phase change regions
40(2). It should be appreciated that phase change regions 40 of
other shapes, sizes, or configurations could also be utilized, such
as an oval or triangular configuration, for example.
[0039] FIG. 3 illustrates a third example embodiment of a composite
construction panel 20(3) which differs from either the first
example embodiment or the second example embodiment primarily by
further comprising a sub-substrate 50. The sub-substrate 50,
situated beneath substrate layer 26, may comprise the same material
as cover layer 28. For example, in an example implementation
sub-substrate 50 may comprise oriented strand board (OSB).
[0040] FIG. 4 illustrates a fourth example embodiment of composite
construction panel 20(4) in which cover layer 28 comprises a
polyiso organic plastic foam which requires few fasteners for
installation, such as a board marketed by Atlas Roofing Corporation
as ACFoam.RTM. HS CoverBoard. FIG. 5 illustrates a fifth example
embodiment of composite construction panel 20(5) in which both
cover layer 28 and sub-substrate 50 comprise the board marketed by
Atlas Roofing Corporation as ACFoam.RTM. HS CoverBoard.
[0041] An example method of fabricating the composite construction
panel (e.g., of the first through fifth embodiments hereof) is
shown in FIG. 6. Act 6-1 comprises adhering (e.g., gluing)
insulation layer 30 to an underside of cover layer 28. Act 6-2
comprises adhering (e.g., laminating) phase change mat 22 to a top
surface of substrate layer 26. Thereafter, as act 6-3 the spacers
32 (which serve as cross vent risers) are adhered (e.g., laminated)
onto substrate layer 26. For example, spacers 32 may be adhered at
the end edges and at 16 inches centered. Then, as act 6-4, the
assembly comprising substrate layer 26 with both the phase change
mat 22 and spacers 32 adhered thereto is laminated to an underside
or bottom surface of insulation layer 30. In this arrangement, when
the insulation layer 30 is a polyiso sheathing (such as Energy
Shield.RTM.), the bottom surface is considered to be that which has
the printed side. It should be noted that various layers can be
coupled to one another either directly or indirectly, as described
herein.
[0042] FIG. 7 illustrates a sixth example embodiment of composite
construction panel 20(7). In the composite construction panel
20(7), the phase change mat 22 has a cover layer of polyiso foam 60
poured or otherwise formed on top thereof. In the sixth example
embodiment, the phase change regions 40 of phase change mat 22 are
thus embedded in polyiso foam cover layer 60.
[0043] In the sixth example embodiment, as in other example
embodiments, the phase change mat 22 does not necessarily have to
be a one-piece mat. If desired, plural phase change mats 22 can be
laid or positioned adjacent one another, either in the width or
length direction, in order to achieve the essentially complete
footprint of the respective embodiment of the composite
construction panel.
[0044] FIG. 9 illustrates another example embodiment. In the
embodiment of FIG. 9, a composite construction panel 20 comprises a
substrate layer 26, a cover layer 28 over the substrate layer 26
and separated from the substrate layer 26 by one or more first
spacers 32a, and a plurality of mats 22a and 22b disposed between
the substrate layer 26 and the cover layer 28, wherein the mats 22a
and 22b are vertically separated from one another in a stacked
configuration by one or more second spacers 32b and comprise at
least one phase change material disposed in at least one phase
change region (40a, 40b). First mat 22a comprises a first phase
change material disposed in a first phase change region 40a and
second mat 22b comprises a second phase change material disposed in
a second phase change region 40b, wherein the first and second
phase change materials are differing phase change materials. The
differing phase change materials, in some embodiments, have
differing chemical compositions and/or thermal properties. For
example, in some embodiments, a first PCM has a transition
temperature above about 30.degree. C. and a second PCM has a
transition temperature below about 30.degree. C. In some
embodiments, the first PCM has a phase transition temperature
between about 30.degree. C. and about 50.degree. C. or between
about 30.degree. C. and about 40.degree. C., and the second PCM has
a phase transition temperature between about 15.degree. C. and
about 29.degree. C., between about 20.degree. C. and about
29.degree. C., or between about 20.degree. C. and about 27.degree.
C. Therefore, in the embodiment of FIG. 9, the PCM of the mat 20a
closer to the cover layer 28 (which is generally disposed closer to
the exterior of the building or building component) has a higher
phase transition temperature than the PCM of the mat 20b closer to
the substrate layer 26 (which is generally disposed closer to the
interior of the building). This arrangement of PCMs can permit
efficient insulation operation of the composite construction panel
20. Other phase transition temperatures are also possible. In some
embodiments, for instance, the first PCM has a phase transition
temperature lower than the phase transition temperature of the
second PCM. Any combination of phase transition temperatures not
inconsistent with the objectives of the present invention may be
used. Moreover, selection of PCM phase transition temperatures can
be based on the building application and/or the average external
temperature. Similarly, other design parameters can also be chosen
based on the application. For example, for a ceiling or roof
application, a composite construction panel described herein can
comprise a thick foam cover layer, a first mat adjacent the cover
layer comprising a first PCM having a phase transition temperature
between about 30.degree. C. and about 50.degree. C., a thin foam
substrate layer, and a second mat adjacent the substrate layer
comprising a second PCM having a phase transition temperature
between about 15.degree. C. and about 29.degree. C.
[0045] FIG. 10 illustrates a top view of a composite panel
according to another example embodiment. In the example embodiment
of FIG. 10, a composite construction panel 20 comprises a substrate
layer (not shown), a cover layer (not shown) over the substrate
layer and separated from the substrate layer by one or more first
spacers (not shown), and at least one mat 22 disposed between the
substrate layer and the cover layer, wherein the mat comprises a
plurality of phase change regions 40a, 40b, 40c, and 40d arranged
in a plurality of rows 42a, 42b, 42c, and 42d, respectively,
wherein a first row (e.g., 42a) comprises a first phase change
material and a second row (e.g., 42b) comprises a second phase
change material, the first and second phase change materials being
differing phase change materials. As described above, the differing
phase change materials, in some embodiments, can have differing
chemical compositions and/or differing thermal properties. In some
embodiments, for instance, the first and second phase change
materials have differing phase transition temperatures, including
any combination of differing transition temperatures described
above.
[0046] In addition, in the embodiment of FIG. 10, the plurality of
rows forms a grid pattern of phase change regions. However, other
arrangements of phase change regions are also possible. For
example, in some embodiments, two or more mats are disposed between
the substrate layer and the cover layer laterally (i.e., in the
horizontal or xy-plane, as opposed to stacked vertically in the
z-direction), so that each mat occupies only a portion of the
overall footprint of the panel. The two or more mats can comprise
differing identities or amounts of PCMs, so that the phase change
properties such as the transition temperature of the phase change
regions of the mats can be varied in the lateral or xy-plane in a
"block" or "mat by mat" manner rather than in a "row by row"
manner. The differing mats can also, in some embodiments, have
differing footprints or dimensions in the xy-plane of the
panel.
[0047] Combinations of differing PCMs having differing phase
transition temperatures as described herein, in some embodiments,
permit composite construction panels described herein to be used
without coupling to an air handling system such as an HVAC system.
In some embodiments described herein, it is not necessary to
provide forced air flow in the vent spaces or cross vent channels
of a composite panel described herein. Instead, in some
embodiments, the combination of PCMs provides accelerated phase
transitions without additional air flow. For instance, in some
embodiments, a PCM having a higher phase transition temperature can
help accelerate the freezing of a nearby PCM having a lower phase
transition temperature. Moreover, in some embodiments, such
synergies can be obtained without the use of forced air flows such
as those provided by an HVAC system coupled to the composite
construction panel.
[0048] Alternatively, in other embodiments, a composite
construction panel described herein can be coupled to one or more
air handling devices, such as one or more fans. The fans, in some
embodiments, can be used to ventilate or provide air flow in the
vent spaces and/or cross vent channels. Further, the one or more
fans, in some embodiments, are wind-powered fans. In other
embodiments, the one or more fans are solar-powered. Solar-powered
fans, in some embodiments, can be coupled to one or more
photovoltaic panels or solar cells disposed in or on a building
wherein the composite construction panel is used, including on a
roof of the building.
[0049] Moreover, in some embodiments, the vent spaces and/or cross
vent channels of a composite construction panel described herein
can be sealed. Sealed panels, in some embodiments, prevent or
substantially prevent the air in the vent spaces and/or cross vent
channels from exiting the panel. Therefore, in some embodiments,
the air disposed in the vent spaces or channels can surround and be
in thermal contact with the phase change regions and can serve as a
heat sink, including a static heat sink.
[0050] It should be noted that the various components of composite
construction panels described herein can be formed from any
materials not inconsistent with the objectives of the present
invention. Choice of materials, in some embodiments, can be based
on the desired building application, such as exterior or interior
use. In some embodiments, for example, one or both of the substrate
layer and the cover layer is formed from a foam. Any foam not
inconsistent with the objectives of the present invention may be
used. In some embodiments, for instance, the foam comprises
polyurethane or polyisocyanurate. In other embodiments, the foam
comprises an ester foam, latex foam, neoprene foam, ethafoam, or
polystyrene foam. A foam described herein can be a closed cell foam
or an open cell foam.
[0051] Moreover, in some embodiments, one or more functional
additives are disposed in the foam of a layer described herein. For
example, in some embodiments, a fire retardant or extinguisher is
disposed in the foam. Any fire retardant or extinguisher not
inconsistent with the objectives of the present invention may be
used. In some embodiments, a fire retardant or extinguisher can
comprise an organic composition or an inorganic composition. In
some embodiments, a fire retardant or extinguisher comprises
tris(2-chloro-1-(chloromethyl)ethyl)phosphate. In some embodiments,
a fire retardant or extinguisher comprises aluminum hydroxide
and/or magnesium hydroxide. In some embodiments, a fire retardant
or extinguisher comprises a salt hydrate or a zeolite, including a
natural or synthetic zeolite.
[0052] In other embodiments, a PCM is disposed in the foam of a
layer described herein. Any PCM not inconsistent with the
objectives of the present invention may be used. In some
embodiments, the PCM disposed in a foam described herein differs
from a PCM disposed in another component of the composite panel,
such as a phase change mat. In other embodiments, the PCM of a foam
is the same type of PCM as another PCM of the composite panel.
Thus, in some embodiments, the transition temperature of the PCM of
a foam can be the same or substantially the same as the transition
temperature of a PCM of a mat of the panel. Alternatively, in other
embodiments, the transition temperature of the foam PCM is
relatively high (e.g., above about 30.degree. C. or 50.degree. C.)
if the foam forms a cover layer of the panel, or relatively low
(e.g., below about 30.degree. C. or 27.degree. C.) if the foam
forms a substrate layer of the panel.
[0053] Various layers of composite panels described herein can also
be formed from materials other than foams. For example, in some
embodiments, one or both of the substrate layer and the cover layer
is formed from wood, plywood, particle board, or oriented strand
board. In some embodiments, one or both of the substrate layer and
the cover layer is formed from gypsum board. In some embodiments,
one or both of the substrate layer and the cover layer is formed
from metal, such as aluminum. Again, in some embodiments, the
choice of material can be based on the desired application of the
composite construction panel. For example, panels for use in
ceilings or walls, in some embodiments, can comprise a foam cover
layer and a gypsum board substrate layer, with one or more phase
change mats disposed in between, as described herein.
Alternatively, in other embodiments, a composite panel for use in
ceilings can comprise a foam cover layer and a ceiling tile
substrate layer, with one or more phase change mats disposed in
between. For roofing applications, a composite panel described
herein, in some embodiments, can comprise a wood or metal cover
layer and a foam substrate layer, with one or more phase change
mats disposed in between.
[0054] Moreover, the spacers of a composite panel described herein
can have any construction not inconsistent with the objectives of
the present invention. In some embodiments, a spacer is hollow.
Further, in some embodiments comprising a hollow spacer, one or
more additives can be disposed in the interior of the hollow
spacer. For example, in some embodiments, a fire retardant or
extinguisher is disposed in the interior of the hollow spacer,
including a fire retardant or extinguisher described hereinabove.
In other embodiments, a PCM is disposed in the interior of the
hollow spacer. The PCM of a spacer, in some embodiments, has a
higher transition temperature than a PCM of a phase change mat of
the panel. With this arrangement, in some embodiments, the PCM of
the spacer can absorb some of the thermal energy in the vent space,
thereby facilitating the freezing (or other phase transition) of a
PCM having a lower phase transition temperature.
[0055] It should be understood that features of one or more of the
example embodiments described herein may be included in or combined
with features of other example embodiments. For example, either the
square shape of the phase change regions 40 of the first example
embodiment or the rectangular shape of the second example
embodiment may be utilized in any of the subsequently described
embodiments or even other embodiments encompassed hereby. Moreover,
any feature or characteristic not particularly described with
reference to a certain embodiment may be understood from other
example embodiments.
[0056] FIG. 8 illustrates an energy-harnessing building module or
assembly 70 which illustrates in example, representative fashion
the use or incorporation of a composite construction panel 20
according to any of the example embodiments of composite
construction panels described herein. For sake of convenience FIG.
8 happens to depict incorporation of the composite construction
panel 20 of FIG. 1A, but it should be understood that the
energy-harnessing assembly 70 may include any other or even a
combination of embodiments encompassed hereby, including the
composite construction panel 20(7) of FIG. 7. The energy-harnessing
assembly 70 is shown as comprising an energy-harnessing body 72
which is mounted onto composite construction panel 20. In the
particular example embodiment shown in FIG. 8, energy-harnessing
building body 72 is secured to composite construction panel 20
through fasteners 74. It should be understood that other means of
attachment may instead be provided, such (by way of non-limiting
example) as means for adhering energy-harnessing body 72 to
composite construction panel 20, or interlocking energy-harnessing
body 72 onto composite construction panel 20.
[0057] The energy-harnessing body 72 may comprise any suitable
energy-harnessing structure, such as a solar cell, a photovoltaic
cell, or any other module or structure which converts radiant or
thermal energy into electrical current or voltage. The
energy-harnessing building body 72 may also, in addition to or
instead of collecting energy, collect and channel precipitation or
other fluids.
[0058] The energy-harnessing body 72 may take the shape or
configuration of a panel, a module, or a shingle. Each
energy-harnessing building assembly 70 may host or have mounted
thereon one or more energy-harnessing bodies 72, e.g., plural
modules, panels, or shingles (e.g., photovoltaic shingles).
[0059] For one or more of the embodiments described herein or
encompassed hereby, the phase change material 44 may take any
suitable form of known phase change materials, and thus in at least
one of its phases may be in a granular or powder form, a gel, or a
liquid. An example phase change mat 22 suitable for use in any of
the example embodiments described herein is a mat marketed by Phase
Change Energy Solutions, Asheboro, N.C., USA, as BioPCM.TM. or
ThermaMat.TM.. The phase change material 44 included in such phase
change mat 22 may be a solid or a gel above or below a transition
temperature. In some embodiments, a phase change material described
herein comprises a paraffin, wax, salt hydrate, fatty acid,
derivative of a fatty acid, fatty alcohol, ester, or mixture
thereof. In some embodiments, emulsifiers, thickening agents, cross
linkers, fire retardants and/or extinguishers are added as
components of a PCM. In some implementations, the phase change
component of the phase change material 44 has a gel physical state
at 27.degree. C., a density in a range of 0.8 to 0.9; and a boiling
point above 249.degree. C. The phase change mat 22 may also have a
fire suppression component and a film component. The film component
may be, e.g., a multilayer film having thickness of, for example,
0.020 inches, and may be of the thermoplastic olefin polymer
family. For example, in an example implementation the film
component may comprise a blend of low and high density polyethylene
(CAS: 9002-88-4); linear low density polyethylene (CAS: 2521302-9);
and nylon 6 (CAS: 25038-54-4). For an example, non-limiting
implementation additives for the film component may include up to
0.03% by weight of amorphous silica (CAS: 60676-86-0); calcium
carbonate (CAS: 471-34-1); cristobalite (CAS: 14464-46-1);
crystalline silica (CAS: 15468-32-3); Erucyl amide (CAS: 112-84-5);
and flux-calcined diatomaceous earth (CAS: 68855-54-9). The silica,
cristobalite, diatomaceous earth and carbon black additives may be
encapsulated in the thermoplastic resin.
[0060] In some example embodiments the phase change mat 22 may also
be fabricated in accordance with or understood from U.S. patent
application Ser. No. 12/448,001, filed Jan. 17, 2001, and published
as U.S. Patent Publication No. 2010/0127000, which is incorporated
herein by reference in its entirety.
[0061] Although the description above contains many specificities,
these should not be construed as limiting the scope of the
invention but as merely providing illustrations of some of the
presently preferred embodiments of this invention. It will be
appreciated that the scope of the present invention fully
encompasses other embodiments which may become obvious to those
skilled in the art, and that the scope of the present invention is
accordingly not to be limited. Reference to an element in the
singular is not intended to mean "one and only one" unless
explicitly so stated, but rather "one or more." All structural and
functional equivalents to the elements of the above-described
embodiments that are known to those of ordinary skill in the art
are expressly incorporated herein by reference and are intended to
be encompassed hereby. Moreover, it is not necessary for a device
or method to address each and every problem sought to be solved by
the present invention, for it to be encompassed hereby.
* * * * *