Structural insulated roof panels with rigid foam core

• US 20090235598A1
• Filed: 03/20/2008
• Published: 09/24/2009
• Est. Priority Date: 03/20/2008
• Status: Active Grant

• Current Assignee: Funform LLC
• Original Assignee: Kenneth Andrew Miller
• Inventors: Miller, Kenneth Andrew
• Granted Patent: US 8,234,833 B2
• Time in Patent Office: Days
• US Class Current: 52/309.800
• CPC Class Codes: E04B 7/22 the slabs having insulating properties, e.g. laminated with layers of insulating material
• CPC Class Codes: E04C 2/22 reinforced E04C2/205 takes precedence
• CPC Class Codes: E04D 3/352 at least one insulating layer being located between non-insulating layers, e.g. double skin slabs or sheets

Abstract

A structural insulated roof panel with a rigid foam core is disclosed. A particular embodiment includes a rigid foam core having first and second faces, a plurality of support channels being formed on the first and second faces of the rigid foam core, each of the support channels being formed in the rigid foam core with at least one bend; and a plurality of supports being insertable into the plurality of support channels such that at least one face of each of the plurality of supports is external to the first and second faces of the rigid foam core and substantially flush with a face of the rigid foam core, each of the plurality of supports being fabricated using at least four bends to produce a support that fits within one of the plurality of support channels.

Claims

1. A structural insulated roof panel comprising:

a rigid foam core having first and second faces, a plurality of support channels being formed on the first and second faces of the rigid foam core, each of the support channels being formed in the rigid foam core with at least one bend, the plurality of support channels being formed as voids in the rigid foam core; and

a plurality of supports being insertable into the plurality of support channels such that at least one face of each of the plurality of supports is external to the first and second faces of the rigid foam core and substantially flush with a face of the rigid foam core, each of the plurality of supports being fabricated using at least four bends to produce a support that fits within one of the plurality of support channels.

2. The structural insulated roof panel as claimed in claim 1 including a support screw connecting at least two of the plurality of supports of the structural insulated roof panel.

3. The structural insulated roof panel as claimed in claim 1 wherein the plurality of supports of the structural insulated roof panel are of two differing types, a first type of support having at least four bends and a second type of support having at least six bends.

4. The structural insulated roof panel as claimed in claim 1 including a strap to join the structural insulated roof panel with a structural insulated wall panel in a substantially perpendicular arrangement.

5. The structural insulated roof panel as claimed in claim 1 including an assembly to join two structural insulated roof panels with rigid foam cores at a building truss.

6. The structural insulated roof panel as claimed in claim 1 including an assembly of a cantilevered structural insulated roof panel with a rigid foam core as joined with a structural insulated wall panel with a rigid foam core and configured for a load-bearing condition.

7. The structural insulated roof panel as claimed in claim 1 including an assembly of a structural insulated roof panel with a rigid foam core as joined with a structural insulated wall panel with a rigid foam core and configured for a load-bearing condition.

8. The structural insulated roof panel as claimed in claim 1 including an assembly of a structural insulated roof panel with a rigid foam core as joined with a structural insulated wall panel with a rigid foam core and configured for a non-load-bearing condition.

9. The structural insulated roof panel as claimed in claim 1 including an assembly of a cantilevered structural insulated roof panel with a rigid foam core as joined with a structural insulated wall panel with a rigid foam core and configured for a non-load-bearing condition.

10. The structural insulated roof panel as claimed in claim 1 including an assembly of a structural insulated roof panel with a rigid foam core as joined with a structural insulated wall panel with a rigid foam core.

11. A method comprising:

forming a plurality of support channels on first and second faces of a rigid foam core, each of the support channels being formed in the rigid foam core with at least one bend, the plurality of support channels being formed as voids in the rigid foam core; and

inserting a plurality of supports into the plurality of support channels such that at least one face of each of the plurality of supports is external to the first and second faces of the rigid foam core and substantially flush with a face of the rigid foam core, each of the plurality of supports being fabricated using at least four bends to produce a support that fits within one of the plurality of support channels.

12. The method as claimed in claim 11 including connecting at least two of the plurality of supports of the structural insulated roof panel with support screws.

13. The method as claimed in claim 11 wherein the plurality of supports are of two differing types, a first type of support having at least four bends and a second type of support having at least six bends.

14. The method as claimed in claim 11 including joining a structural insulated roof panel with a structural insulated wall panel in a substantially perpendicular arrangement using a strap.

15. The method as claimed in claim 11 including joining two structural insulated roof panels with rigid foam cores at a building truss.

16. The method as claimed in claim 11 including joining a cantilevered structural insulated roof panel with a rigid foam core with a structural insulated wall panel with a rigid foam core as configured for a load-bearing condition.

17. The method as claimed in claim 11 including joining a structural insulated roof panel with a rigid foam core with a structural insulated wall panel with a rigid foam core as configured for a load-bearing condition.

18. The method as claimed in claim 11 including joining a structural insulated roof panel with a rigid foam core with a structural insulated wall panel with a rigid foam core as configured for a non-load-bearing condition.

19. The method as claimed in claim 11 including joining a cantilevered structural insulated roof panel with a rigid foam core with a structural insulated wall panel with a rigid foam core as configured for a non-load-bearing condition.

20. The method as claimed in claim 11 including joining a structural insulated roof panel with a rigid foam core with a structural insulated wall panel with a rigid foam core.