Structural insulated roof panels with rigid foam core

  • US 8,234,833 B2
  • Filed: 03/20/2008
  • Issued: 08/07/2012
  • Est. Priority Date: 03/20/2008
  • Status: Active Grant
First Claim
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1. A method of fabricating a structural insulated roof panel, the 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 as voids cut into the rigid foam core thereby enabling slideable insertion of a support into the void of each support channel, first support channels on the first face of the rigid foam core being formed as voids with two bends and configured to fit corresponding supports having four bends, second support channels on the second face of the rigid foam core being formed as voids with four bends and configured to fit corresponding supports having six bends;

    inserting a plurality of first supports into the voids provided by the first support channels such that one face of each of the plurality of first supports being external to the first face of the rigid foam core and substantially flush with the first face of the rigid foam core, each of the plurality of first supports being fabricated as a structure having four bends and including a portion corresponding to a shape of the first support channels, wherein each of the plurality of first supports has a hat channel shape in cross-section; and

    inserting a plurality of second supports into the voids provided by the second support channels such that one face of each of the plurality of second supports being external to the second face of the rigid foam core and substantially flush with the second face of the rigid foam core, each of the plurality of second supports being fabricated as a structure having six bends and including a portion corresponding to a shape of the second support channels.

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