BUILDINGS WITH CONTINUOUS INSULATION BRIDGING A ROOF ASSEMBLY AND A FLOOR ASSEMBLY

• US 20200141116A1
• Filed: 11/05/2018
• Published: 05/07/2020
• Est. Priority Date: 11/05/2018
• Status: Active Grant

• Current Assignee: Covestro LLC (Covestro AG)
• Original Assignee: Covestro LLC (Covestro AG)
• Inventors: Lambach, James L., Baily, David M.
• Granted Patent: US 10,640,973 B1
• Time in Patent Office: Days
• CPC Class Codes: B32B 15/046 of foam
• CPC Class Codes: B32B 15/082 comprising vinyl resins; comprising acrylic resins
• CPC Class Codes: B32B 15/095 comprising polyurethanes
• CPC Class Codes: B32B 15/20 comprising aluminium or copper B32B15/016 and B32B15/017 take precedence
• CPC Class Codes: B32B 2266/0228 Aromatic vinyl resin, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 2266/0278 Polyurethane
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2419/06 Roofs, roof membranes
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: E04B 1/7612 in combination with an air space
• CPC Class Codes: E04B 1/7654 comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings
• CPC Class Codes: E04B 7/022 consisting of a plurality of parallel similar trusses or portal frames
• CPC Class Codes: E04B 7/026 consisting of prefabricated modules, e.g. box-like or cell-like units E04B7/24 takes precedence
• CPC Class Codes: E04B 7/04 supported by horizontal beams or the equivalent resting on the walls E04B7/06 takes precedence
• CPC Class Codes: E04D 13/1625 with means for supporting the insulating material between the purlins or rafters insulating layers disposed between two longitudinal supporting elements E04B1/7654
• CPC Class Codes: F24S 20/67 in the form of roof constructions in the form of shingles or tiles F24S20/69
• CPC Class Codes: F24S 2020/11 in the form of multiple rows and multiple columns, all solar modules being coplanar
• CPC Class Codes: H02S 20/23 specially adapted for roof structures
• CPC Class Codes: H02S 20/30 Supporting structures being movable or adjustable, e.g. for angle adjustment
• CPC Class Codes: H02S 30/10 Frame structures
• CPC Class Codes: H02S 40/345 : with cooling means associated with the electrical connection means, e.g. cooling means associated with or applied to the junction box cooling means for PV cells H01L31/052, for PV modules H02S40/42
• CPC Class Codes: H02S 40/425 : using a gaseous or a liquid coolant, e.g. air flow ventilation, water circulation
• CPC Class Codes: Y02B 10/10 : Photovoltaic [PV]
• CPC Class Codes: Y02B 10/20 : Solar thermal
• CPC Class Codes: Y02E 10/40 : Solar thermal energy, e.g. solar towers
• CPC Class Codes: Y02E 10/50 : Photovoltaic [PV] energy

Abstract

Insulated buildings are described. The building include: (a) a sloped roof that is a prefabricated insulated roof assembly; (b) a generally horizontally arranged flooring assembly having an end that is arranged over a wall structure and under the sloped roof assembly; (c) a sloped member that is arranged over the end of the flooring assembly that is over the wall structure, and (d) a rigid foam insulation member arranged in the cavity of the roof assembly so as to bridge a lower surface of a rigid foam insulation board in the roof assembly to the sloped member.

Claims

1. A building comprising:

(a) a sloped roof comprising an insulated roof assembly;

(b) a generally horizontally arranged flooring assembly comprising an end thereof that is arranged over a wall structure and under the sloped roof assembly;

(c) a sloped member that is arranged over the end of the flooring assembly that is over the wall structure, and

(d) a rigid foam insulation member arranged in a cavity of the roof assembly so as to bridge a lower surface of a rigid foam insulation board in the roof assembly to the sloped member,

wherein the insulated roof assembly comprises;

(1) a sheathing panel comprising an upper surface and a lower surface;

(2) a plurality of I-joists positioned in a generally parallel relationship to each other, the I-joists comprising;

(i) an upper flange,

(ii) a lower flange, and

(iii) a web extending between the upper flange and the lower flange,

wherein the lower surface of the sheathing panel faces an upper surface of the upper flange of the I-joists so that the sheathing panel and the I-joists define the cavity;

(3) a generally planar first rigid foam insulation board comprising;

(i) an upper surface,

(ii) a lower surface,

(iii) a first side, and

(iv) a second side that is opposite of the first side,

wherein the first rigid foam insulation board is positioned in the cavity such that;

(i) the upper surface of the first side of the first rigid foam insulation board faces the lower surface of the upper flange of a first I-joist,

(ii) the upper surface of the second side of the first rigid foam insulation board faces the lower surface of the upper flange of a second I-joist,

(iii) an edge of the first side of the first rigid foam insulation board faces the web of the first I-joist, and

(vi) an edge of the second side of the first rigid foam insulation board faces the web of the second I-joist.

2. The building of claim 1, wherein the insulated roof assembly comprises a generally planar second rigid foam insulation board comprising:

(i) an upper surface,

(ii) a lower surface,

(iii) a first side, and

(iv) a second side that is opposite of the first side,

wherein the second rigid foam insulation board is positioned in the cavity such that;

(i) the upper surface of the second rigid foam insulation board faces the lower surface of the first rigid foam insulation board,

(ii) the lower surface of the second rigid foam insulation board faces the upper surface of the lower flange of a first I-joist in a spaced-apart relationship at the first side of the second rigid foam insulation board,

(iii) the lower surface of the second rigid foam insulation board faces the upper surface of the lower flange of a second I-joist in a spaced-apart relationship at the second side of the second rigid foam insulation board,

(iv) an outer edge of the first side of the second rigid foam insulation board faces the web of the first I-joist, and

(v) an outer edge of the second side of the second rigid foam insulation board faces the web of the second I-joist.

3. The building of claim 1, wherein the first rigid foam insulation board and the rigid foam insulation member each comprise a polyisocyanurate foam board, an expanded polystyrene foam board, or an extruded polystyrene foam board.

4. The building of claim 2, wherein the first rigid foam insulation board and the second rigid foam insulation board each comprise a facer material on an upper face and/or a lower face of a foam layer.

5. The building of claim 4, wherein the first rigid foam insulation board has a thickness of 2½

to 4 inches and comprises a polyisocyanurate foam layer and an aluminum foil facer or coated glass facer adhered to each side of the polyisocyanurate foam layer and the second rigid foam insulation board has a thickness of 1½

to 2 inches and comprises a polyisocyanurate foam layer and a glass fiber reinforced foil facer material adhered to each side of the polyisocyanurate foam layer.

6. The building of claim 1, wherein an outer edge of the first side of the first rigid foam insulation board abuts the web of the first I-joist and an outer edge of the second side of the first rigid foam insulation board abuts the web of the second I-joist, so that the outer edges are not in a spaced-apart relationship relative to web of the first I-joist and the web of the second I-joist.

7. The building of claim 2, wherein the upper surface of the second rigid foam insulation board abuts the lower surface of the first rigid foam insulation board so that first rigid foam insulation board and second rigid foam insulation board are not in a spaced-apart relationship relative to each other.

8. The building of claim 2, wherein the upper surface of the second rigid foam insulation board faces the lower surface of the first rigid foam insulation board such that first rigid foam insulation board and second rigid foam insulation board are in a spaced-apart relationship.

9. The building of claim 2, wherein:

(i) the lower surface of the second rigid foam insulation board faces the upper surface of the lower flange of a first I-joist at the first side of the second rigid foam insulation board in a spaced-apart relationship, and

(ii) the lower surface of the second rigid foam insulation board faces the upper surface of the lower flange of a second I-joist at the second side of the second rigid insulation board in a spaced-apart relationship,

such that a gap is formed between the lower surface of the second rigid foam insulation board and the lower surface of the lower flanges of the first I-joist and the second I-joist, the gap having a height of 1¼

to 7 inches.

10. The building of claim 9, wherein the outer edge of the first side of the second rigid foam insulation board abuts the web of the first I-joist and the outer edge of the second side of the second rigid foam insulation board abuts the web of the second I-joist so that the outer edges are not in a spaced-apart relationship relative to web of the first I-joist and the web of the second I-joist.

11. The building of claim 2, wherein the second rigid foam insulation board is designed such that according to the 2018 International Residential Code®

(“

IRC”

) Section 2603.9, compliance with the requirements of IRC Sections 2603.4 through 2603.7 is not required.

12. The building of claim 2, wherein the combined thermal insulating value of the first rigid foam insulation board and the second rigid foam insulation board is at least R-30 determined per ASTM C 518-17 in accordance with ASTM C-1289-18.

13. The building of claim 2, wherein the first rigid foam insulation board and the second rigid foam insulation board each have a thickness ranging from 1 inch to 4 inch and the combined thermal insulating value of the first rigid foam insulation board and the second rigid foam insulation board is at least R-30 determined per ASTM C 518-17 in accordance with ASTM C-1289-18.

14. The building of claim 1, wherein the flooring assembly comprises:

(i) a blocking member that spans between floor joists and an end thereof that overlies the wall structure, and

(ii) insulation that is positioned between the floor joists and adjacent to the blocking member.

15. The building of claim 1, wherein the angle of sloped member generally correspond to the pitch of the sloped roof assembly.

16. The building of claim 15, wherein the sloped member comprises a generally horizontally oriented side that rests atop the flooring assembly and a sloped side that rests against the lower surface of the lower flange of the I-joists in the sloped roof assembly.

17. The building of claim 16, wherein the sloped member is an elongated member having a length that spans two or more I-joists.

18. The building of claim 16, wherein the rigid foam insulation member rests on the sloped side of the sloped member and is an elongated member having a length that spans two or more I-joists.

19. The building of claim 18, wherein the rigid foam insulation member is dimensioned so that it has a width at least corresponding to the width of sloped side of sloped member and a height that corresponds at least to the height of a gap in the cavity of the sloped roof assembly.

20. The building of claim 1, wherein the wall structure is a foam wall structure that comprises:

a) a frame comprising;

a first member;

a second member spaced apart from the first member; and

two side members extending between the first and second members, wherein the first member, second member, and two side members each have a front surface and a rear surface that form the front frame surface and the rear frame surface of the frame;

b) at least one primary support member positioned between the two side members and extending between the first and second member, wherein the primary support member defines a front primary support surface and an opposite rear primary support surface corresponding to the front frame surface and rear frame surface;

c) a slab of rigid foam insulation board attached to one of at least a portion of the front frame surface or at least a portion of the front primary support surface and optionally the front primary support surface of the at least one primary support members, such that the rigid foam insulation board, the first and second members, the two side members and the at least one primary support members define one or more voids within the frame;

d) a foam layer received within at least a portion of one of the voids within the frame, wherein the foam layer adheres to at least a portion of the rigid foam insulation board.

21. The building of claim 1, wherein the upper flange, the lower flange, and the web of the plurality of I-joists are all constructed of wood.