Vented insulation panel with reflecting surface

Abstract

A thermally insulative building construction panel (10) is comprised of a first or top sheet (20) that is a rigid nail-anchoring material; a second sheet (22) comprised of aluminum foil firmly adhered to the top sheet (20); and, a third or bottom sheet (26) comprised of an insulation material comprising low density foam insulation. A plurality of spacer members (24) are sandwiched in fixed positions between the second sheet (22) and the third (bottom) sheet (26) for defining air channels (25) between the sheets and between the spacer members themselves to permit multi-dimensional air flow substantially throughout the panel. In a first example embodiment, plural discrete spacer members are arranged in a pattern such that, for the discrete spacer members arranged in any direction of alignment, an air channel extends perpendicular to the direction of alignment. In a second example embodiment, elongated plural spacer members are configured to permit multi-dimensional air flow substantially throughout the panel by having a surface thereof formed in a square wave shape with alternating crests and troughs which essentially repeat along a major dimension of the spacer member. In a third example embodiment, panels of either the first example embodiment or the second example embodiment have their first sheet formed with a smaller surface area than the third sheet to facilitate formation of an expansion gap between adjacent panels.

Description

BACKGROUND

This application claims the priority and benefit of U.S. Provisional Patent Application 60/638,513, filed Dec. 27, 2004, which is incorporated herein by reference in its entirety.

1. Field of the Invention

The field of the invention pertains to building and insulation panels used in building construction, and particularly to structural panels used as support for the waterproofing membranes, such as shingles, for roofing construction.

2. Related Art and Other Considerations

Roofing membranes, including roofing shingles and other forms of roofing cover, are widely used in the building construction industry. The support panel underneath a roofing membrane resides in one of the most destructive environments known to the industry. Direct sunlight on the waterproofing membrane creates temperatures in excess of 100° F. many days during the year. Both the membrane and the support panel must be fabricated so they can endure this harsh and hostile environment. At the same time, a high priority for the owners and/or residents of the building covered by the membrane and support panel is a comfortable environment indoors, and at the lowest possible cost. The owners desire the lowest possible “up-front” cost as well as the lowest possible daily operating costs. With these considerations in mind, many roofing products have been proposed and have had differing degrees of success and acceptability.

Oddly enough, an effective prefabricated thermal insulation panel is inherently self-destructing. That is, in serving its purpose of insulating a building for the purpose of conserving energy, the panel stores high levels of heat. Such intense heat may be deleterious to the panel structure per se. This heat build-up problem is especially acute in the roofing environment. In the roofmg environment, a dual panel assembly is often used as the prefabricated thermal insulation panel. A dual-panel assembly essentially comprises two parallel panels or sheets. The roofing membrane is nailed or adhered to the upper of the two parallel panels. The heat build-up problem is particularly severe in older forms of dual-panel assemblies in which the high efficiency plastic foam insulation panel is adhered directly to a member such as a nailing-base panel.

A more recent example of a dual-panel assembly is illustrated in U.S. Pat. No. 5,433,050, which is incorporated herein by reference. The improved dual-panel assembly of U.S. Pat. No. 5,433,050 separates the two panels by air channels that allow air to pass between the top deck (also known as the nailing base) and the underlying insulation board, thus causing a cooling effect on all components. Embodiments of U. S. Pat. No. 5,433,050 as well as a dual-panel assembly roofing product marketed by Atlas Roofing Corporation as Vented-R Nail Base are particularly advantageous in using, e.g., high R-Value spacer members to space the two panels and thus form the air channels.

By contrast, inferior products utilize wooden “furring strips” as the spacer strips. Such wooden furring strips are often less than three inches wide, and thus may require as many as five strips to be placed within a forty-eight inch length. When wood furring strips are used as the spacer members to create the air channels, the wood lowers the thermal resistance values (e.g., increases thermal conductance) of the insulative building panel within the area where wood furring strips are used. In the winter time in northern geographical regions, these areas may be seen on a roof as strips of melted snow.

In more recent years, many products have been introduced that utilize the special properties of aluminum. Highly polished aluminum foil, or aluminum sheets, have the unique property of reflecting up to ninety-seven-percent (97%) of the incoming radiant energy. If it has been heated by conductance heat or convection heat, that same aluminum will only radiate about three-percent (3%) of the incident heat energy. This unique property of aluminum is called “emissivity.” Emissivity can be defined as the relative ability of a surface to emit radiation, measured as the ratio of the energy radiated by a surface to the energy radiated by a black body at the same temperature.

It is known to adhere aluminum foil to a board known as Oriented Strand Board (hereinafter, “OSB”). The primary use of aluminum foil-adhered OSB is for roofing sheathing. In such use generally manufacturers require the aluminum foil be installed facing the open attic space. OSB products can also be used in walls, facing either toward the interior or exterior. Two examples of such products include LuminOX® (previously marketed by Potlatch Corporation of Spokane, Wash., see, e.g., www.potlatchcorp.com). and “Solar Board” (produced by Norbord Industries of Toronto, Canada).

In the earliest days when aluminum foil was promoted as a viable insulation material, the promoters were largely unheard-of companies, and the touted benefits tended to be in excess of actual values. But that has all changed in recent years since governments have taken a keen interest in building envelope insulation. For example, the United States Department of Energy (“DOE”) received mandates to improve all energy-saving materials and systems. DOE involvement provided impetus in energy research and building insulation in particular. For example, the Oak Ridge National Laboratories (“ORNL”), which is operated by the US DOE, has massive amounts of information to help architects, engineers, and other building construction professionals utilize energy-related facts. See, for example, the fact sheet located at: www.ornl.gov/roofs+walls/radiant/, which has eight sections comprising a document with over a dozen pages of help and advice. DOE also has an Office of Energy Efficiency and Renewable Energy (EERE), which posts multiple web pages of extensive information on radiant barrier insulation at EERE.gov.

Although a good radiant barrier does have some insulative value, it may often be difficult to measure the actual “R-Value” of a composite product which uses the radiant barrier in some configurations.

It is therefore an object of the present invention to provide a vented, insulative building panel that also utilizes the special emissivity properties of aluminum and has good insulation properties.

BRIEF SUMMARY

A multiple component panel assembly comprises a first sheet of a rigid nail-anchoring material; a second sheet comprising a layer of aluminum foil that is securely adhered to the first sheet; and, a third sheet comprising an insulation material. Spacer members are provided in a spacer layer between the second and third sheets, the spacer members being configured to permit multi-dimensional air flow substantially throughout the panel.

In a first example embodiment, plural discrete spacer members are connected in fixed positions between the second sheet and the third sheet for defining air channels between the sheets and between the spacer members themselves. The plural discrete spacer members are arranged in a pattern to permit the multi-dimensional air flow substantially throughout the panel. The pattern being such that, for the discrete spacer members arranged in an any direction of alignment, an air channel extends perpendicular to the direction of alignment.

In a second example embodiment, elongated plural spacer members are configured to permit multi-dimensional air flow substantially throughout the panel by having a surface thereof formed in a square wave shape with alternating crests and troughs which essentially repeat along a major dimension of the spacer member. In a non-limiting example implementation, each trough extends to a depth of approximately one half the thickness of the spacer member to define one of the air channels through the spacer member in a length direction of the panel. In an illustrated example embodiment, the crests and troughs have essentially a same periodicity or length along a width dimension of the panel, except for two extreme-most crests and troughs at each end thereof.

In a third example embodiment, panels of either the first example embodiment or the second example embodiment have their first sheet formed with a smaller surface area than the third to facilitate formation of a gap between adjacent panels.

In an illustrated implementation, the first sheet has a density in excess of 25 pounds/cubic foot and the third sheet has a a density less than 5 pounds/cubic foot and having an insulative “R” value in excess of 3.0 per inch thickness. The first sheet comprises of a material selected from the group consisting of plywood, Waferboard, Oriented Strand Board (OSB), and particle board. The third sheet is comprised of an insulation material selected from the group consisting of polyurethane modified polyisocyanurate foam, polyurethane foam, phenolic-formaldehyde foam, and polystyrene foam. The spacer members are preferably comprised of an insulation material, but can also be formed from solid wood, the materials sutiable for the first sheet, or a prefabricated metal material.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a radiant-vented nail base insulation panel according to an example embodiment.

FIG. 2 is a side view of the radiant-vented insulation panel of FIG. 1.

FIG. 3 is an end view of the radiant-vented insulation panel of FIG. 1.

FIG. 4 is a sectioned side view of a spacer member which comprises the panel of FIG. 1.

FIG. 5 is a plan view of a radiant-vented nail base insulation panel according to another example embodiment.

FIG. 6 is a plan view of a radiant-vented nail base insulation panel according to yet another example embodiment.

FIG. 7 is a plan view of a spacer member which comprises the panel of FIG. 6.

FIG. 8 is a side view of the spacer member which comprises the panel of FIG. 6.

FIG. 9 is an isometric view of the panel of FIG. 6.

FIG. 10A is a plan view of a radiant-vented nail base insulation panel according to still another example embodiment; FIG. 10B is a side view of two adjacent panels of the embodiment of FIG. 10A shown from a length dimension; and FIG. 10C is a side view of two adjacent panels of the embodiment of FIG. 10A shown from a width dimension.

FIG. 11 is a partial perspective view, partially sectioned, of a radiant-vented insulation panel of the embodiment of FIG. 1 installed on a sloped roof.

DETAILED DESCRIPTION

In the following description, for purposes of explanation and not limitation, specific details are set forth such as particular compositions, techniques, etc. in order to provide a thorough understanding. 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. In other instances, detailed descriptions of well-known substances and methods are omitted so as not to obscure the description of the present invention with unnecessary detail.

FIG. 1 and FIG. 2 show a prefabricated radiant-vented insulation panel 10. The panel 10 comprises a first panel or sheet 20; a second panel or sheet 22, a plurality of spacer members 24; and a third panel or sheet 26. The sheets 20, 22 and 26 lie in parallel planes. While in one example implementation sheets 20 and 22 may lie in contacting relation, sheets 22 and 26 are maintained in spaced-apart, parallel relationship by the spacer members 24. Spacer members 24 are sandwiched in fixed positions between the second sheet 22 and the third sheet 26 for defining air channels 25 between the sheets 22 and 26; the air channels 25 also extending between the spacer members 24 themselves.

The first (or “top”) sheet 20, also known as the nail-base panel, is a strong, structural panel such as plywood, particle board, Waferboard, or Oriented Strand Board (“OSB”) that is capable of holding nails or staples indefinitely. The second sheet 22 is in all cases a layer of bright, shiny aluminum foil. The foil sheet 22 is firmly adhered to the nail-base panel 20. The third sheet 26 is a board comprised of plastic foam insulation. The fourth component of panel 10 is a layer of air channels 25 formed between the aluminum foil 22 and the plastic foam insulation board 26. The air channels 25 are created by strategically placed spacer members 24. The spacer members 24 preferably permit air to circulate in all directions.

As shown in FIG. 1, the panel 10 extends across a first dimension as depicted by an arrow 28. In the illustrated embodiment, the panel 10 extends approximately eight feet (96-inches) across the dimension of arrow 28 (sometimes referred to as the “length” dimension) and approximately four feet (48-inches) across the dimension of arrow 30 (sometimes referred to as the “width” dimension).

The spacer members 24 comprise a spacer layer wherein plural, discrete spacer members 24 are arranged in a pattern which permits air to travel both in a length direction and a width direction in the spacer layer of panel 10. In other words, at least one air channel 25 is provided for plural spacer members 24 aligned in an any direction of alignment, the air channel 25 extending perpendicular to the direction of alignment. As such, the spacer members 24 with the air channels 25 provide multi-dimensional air flow substantially throughout the panel 10.

In the illustrated example implementation of the FIG. 1 embodiment, the pattern of the discrete spacer members 24 is a rectangular matrix having three rows and five columns. Each row of discrete spacer members 24 extends along the dimension of arrow 28. Each column extends along direction 30. For the spacer members 24 arranged in a row, e.g., the spacer members 24 extending along the dimension of arrow 28, air channels 25 are provided orthogonally (e.g., extending in the direction of arrow 30). Conversely, for the spacer members 24 arranged in a column, e.g., the spacer members 24 extending along the dimension of arrow 30, air channels 25 aer provided orthogonally (extending in the direction of arrow 28).

In the embodiment of FIG. 1, each spacer member 24 has an essentially rectangular shape, with three of the rectangular spacer members 24 situated in the interior of panel 10 having a full spacer size (e.g., full size along both the length dimension and the width dimension) and rectangular spacer members 24 situated around the perimeter of panel 10 having a truncated spacer size).

In some optional implementations, the spacer members which are situated proximate or around the perimeter of the panel 10 can have a spacer size that is essentially half size in a truncated dimension. For example, the spacer members of the first row of panel 10, e.g., those spacers situated at the top of panel 10 of FIG. 1, can have half the width (in direction of arrow 30) as the full spacers, so that juxtaposition of another panel 10 above the illustrated panel would result in two half-width spacers being juxtaposed in the width direction with a result that the two juxtaposed spacers extend essentially the same extent along the width direction of arrow 30 as would a single full size spacer.

While spacer members 24 of rectangular shape have been illustrated, it will be appreciated that the spacer members 24 can take other shapes, such a triangular, circular, or shapes having more than four edges or sides.

As seen in FIG. 3 and FIG. 4, each spacer member 24 has a thickness 32. As used herein, when referring to the panel 10 per se or any component thereof, the term “thick” or “thickness” refers to a dimension that is perpendicular to the plane in which arrows 28 and 30 lie. As depicted in FIG. 2, the overall composite panel 10 thickness 34 includes the sum of the thicknesses of sheets 20, 22, 26, and spacer members 24. The overall thickness 34 of the entire composite panel 10 is not to be confused with the thickness 32 of the spacer members 24. The spacer thickness 32 is typically used by a customer when ordering product; whereas, the overall panel 10 thickness 34 is typically utilized by a building designer, loading and shipping personnel, and contractors.

FIG. 3 shows the end view of the panel 10, where the length (e.g., major dimension) of each spacer member 24 along the dimension of arrow 30 can be seen. FIG. 4 is a side view of a spacer member which comprises the panel of FIG. 1. FIG. 4 shows the spacer thickness dimension 32, which is typically either 1-inch, 1.5-inches, or 2-inches. The thickness should be such as to facilitate adequate air flow throughout the air channels 25.

Although the drawings of composite panel 10 of FIG. 1, FIG. 2, FIG. 3 and FIG. 4 are not to scale, these drawings do in other respects depict an actual radiant-vented nail base insulation panel according to one example embodiment. The number, location, size, shape, and pattern of arrangement of the spacer material 24 are variables as long as the supporting strength is adequate.

In the example embodiment of FIG. 4, the spacer members 24 are preferably comprised of pieces of polyisocyanurate foam board. Polyisocyanurate foam board generally has two sheets of facer material (e.g., “facers”) which are adhered to and comprised of polyisocyanurate foam core. The facers are preferably strongly adhered to the core. In such embodiment, the rectangular spacer pieces 24 can be up to 8-inches wide and over 12-inches long. In other embodiments, the spacer members 24 can also be formed from other insulation materials such as polyurethane foam, phenolic-formaldehyde foam, and polystyrene foam; from solid wood; from any one or more of the above-listed materials suitable for the first sheet, or a prefabricated metal material.

FIG. 5 shows another embodiment of a radiant-vented nail base insulation panel 10(5). In the embodiment of FIG. 5, wooden strips 24(5) are used for the spacer members. Other layouts (e.g., patterns or arrangements of spacer pieces) also work well when wooden strips are utilized, for which reason FIG. 5 is not meant to be a restrictive design with wood spacers. In the particular embodiment of FIG. 5, the wood pieces 24(5) are about 2-inches wide, 6-inches long, and either 1-inch, 1.5-inches, or 2-inches thick. The wooden spacers 24(5) are preferably equally spaced at five (5) spacers across the forty-eight (48) inch width (e.g., across direction 30), leaving ⅛^th-inch set-back at every edge, and six (6) columns of 5 spacers per-row are equally spaced along the ninety-six (96) inch length (e.g., along direction 28), again leaving ⅛^th-inch set-back at every edge. The set-back allows for thermal expansion and contraction.

FIG. 5 thus depicts an aspect of the technology wherein spacer members are set back or recessed from one or more edges of vented nail base insulation panel assembly. The spacer members may be recessed or set back along each edge of the entire perimeter as shown in FIG. 5, or alternatively recessed from one or more (but not all) selected edges of the panel.

FIG. 6 is a top view of a radiant-vented nail base insulation panel 10(6) wherein specially prepared expanded polystyrene (EPS) foam strips are used for spacer material 24(6). FIG. 7 is a plan view of the specially prepared EPS foam strip spacer member 24(6) for the panel 10(6) of FIG. 6. The EPS foam strip spacer members 24(6) can be 4-inches wide in each spacer location or 4-inches wide when used at the side edges of the composite panel 10(6), or 6-inches wide when used as one of the three (3) interior spacer members 24(6) of the composite panel 10(6).

FIG. 8 is a side view of the EPS foam strip spacer member 24(6) which comprises the panel 10(6) of FIG. 6. FIG. 6 and FIG. 8 show detailed dimensions of one example implementation. These figures and dimensions are not meant in any way to be restrictive or limiting, but only exemplary.

The EPS strips 24(6) have a surface thereof (either top or bottom) configured with a square wave shape, and thereby having alternating crests and troughs which essentially repeat along a major dimension of each strip 24(6). The major dimension of each strip 24(6) is parallel to dimension 30. Each trough extends to a depth of approximately one half the thickness of the strip 24(6). The crests and troughs have essentially a same periodicity or length (e.g., 1 and 1/16 inch) along dimension 30, except for the two extreme-most crests and troughs at each end of spacer 24(6), which are shorter in length (e.g., about ½ inch).

FIG. 9 is an isometric view of panel 10(6) comprised of venting strips 24(6) of FIG. 7 and FIG. 8. The panel 10(6) also employs polyisocyanurate foam board as the bottom layer 26(6) and OSB as the top layer 20. The top layer 20 is used to hold; e.g., shingles, for example, and (in the example implementation) can be about 7/16″ thick.

The materials descriptions for the sheets or layers for any embodiment described herein are also applicable for all other embodiments and implementations described herein or encompassed hereby.

FIG. 10A, FIG. 10B, and FIG. 10C illustrate a third example embodiment of a panel 10(10) wherein the first sheet 20 (and second sheet 22) are formed to have a smaller surface area than the third sheet 26 (e.g., the insulation board) to facilitate formation of an expansion gap G between adjacent panels (see two adjacent panels 10(10)₁ and 10(10)₂ in FIG. 10B and FIG. 10C). In the particular implementation shown in FIG. 10, a bottom edge and left edge of all three layers 20, 22, and 26 are aligned to be “square”, e.g., to have a square edge. However, in view of the slightly smaller surface area or footprint of the first sheet 20 relative to the third sheet 26, the first sheet 20 in recessed approximately ⅛ inch within the top and right edges of the third sheet 26 and the remainder of panel 10(10). The recess of first sheet 20 in this manner provides a slight off set or set back of first sheet 20 panel relative to third sheet 26 and the remainder of the panel. This offset or undersizing of the first sheet 20 facilitates formation of a desirable expansion gap G between adjacent panels. In the particular implementation shown in FIG. 10A, FIG. 10B, and FIG. 10C, the third sheet 26 has a length of eight feet in the dimension of arrow 28 and a width of four feet in the dimension of arrow 30, with the first sheet 20 and the second sheet 22 being sized slightly smaller (e.g., ⅛ inch smaller in each dimension).

It should be understood that more than two edges of the panel could have offset or set back in the manner of FIG. 10A. For example, as an alternative the offset or set back can occur around the entire perimeter of the panel, if desired. Moreover, offset amounts can vary depending on environmental or application issues or manufacturer choice. Further, panels of either the first example embodiment or the second example embodiment have their first sheet formed with a smaller surface area than the third sheet to facilitate formation of the expansion gap between adjacent panels in the same or similar manner as illustrated or described with reference to FIG. 10A-FIG. 10C.

FIG. 11 shows the prefabricated vented insulation panel 10 of the embodiment of FIG. 1 installed in a typical sloped roof environment. While the panel of FIG. 1 is illustrated in FIG. 11, FIG. 11 serves to illustrate generically the mounting of any of the example embodiments described herein. The panel is illustrated as being utilized on a building having vertical studs 40. The studs 40 support roof framing members, with the roof framing members in turn supporting the panel 10. The roof framing members include rafters 42 for supporting under-decking 44. Top plates 46 are employed to fasten the rafters 42 and joists 48 to the studs 40. The rafters 42 are tied together by the structural load-bearing under-decking 44.

Overlying the panel 10 is a conventional roofing membrane system comprising a base sheet 50 overlaid with shingles 52, which act as the waterproofing element on top. A vent cap 54 is provided at the roof ridge. The function of the vent cap 54 is explained in prior art publications, such as U.S. Pat. No. 4,852,314 to Moore, which is incorporated herein by reference. A soffit side-fascia 56 is usually nailed to the ends of the rafters 42 and/or joists 48. If an open-beam (e.g., Cathedral) ceiling design is utilized, (i.e., no joists and no attic), the roof structural under-decking 44 becomes the ceiling. In this case, the space between the rafters 42 must be closed up with vertical wall structures, plus wall plates, against the under-decking 44.

The first sheet 20, also known as the top deck, comprises a rigid nail-anchoring material. The sheet 20 can be any ordinary roofing deck material normally used as a nail base for roofing felt and roofing shingles, such as plywood, Waferboard, Oriented Strand Board (OSB), and particle board. First sheet 20 has a density in excess of 25 lbs./cubic foot, and holds ordinary nail shanks. Some high-density particleboard can be as high as 56 lbs./cubic foot, but the typical nail base board density is 35-45 lbs./ft³. The insulative value of sheet 20 is a maximum of R=1.25 per inch.

The preferred materials for the top sheet 20 are 7/16″ OSB, ½″ plywood, or 7/16″ Waferboard. The most preferred material is OSB, as plywood often has concealed, interior voids.

The spacer members 24 have a generally elongated rectangular shape and, as shown in FIG. 4, are of rectangular cross section. The spacer members of the present invention can be made of any normal building construction material that meets the requirements of dimensions and compressive strength. In this regard, the compressive strength of a spacer material is in excess of 20-pounds-per-square-inch (“psi”). Compressive strength as used herein shall be defined as the amount of force (in psi) needed to deform the material in the Z (vertical) direction by ten percent (10%). The Z, or vertical direction, is that direction depicted in FIG. 4 by the two arrows. The spacer members 24 can be made from a metal material, such as a honeycomb structure made of thin aluminum strips, as well as by other materials including those already mentioned herein.

The second panel or sheet 22, also referred to as layer 22, is highly polished aluminum foil. The aluminum foil can be any caliper (thickness) and any hardness rating. The only requirement is that the sheet be placed with the shiny, highly polished surface facing away from the top layer 20, to which the aluminum foil 22 is completely and firmly adhered. No foil spots (areas) should be left loose from board 20.

The thickness of the aluminum foil sheet utilized to provide radiated energy reflectance or low radiation energy emissivity is not critical. However, the aluminum sheet should not be so thin that “jobsite friction” will tear open a hole even if securely adhered to the OSB (or other) nailing base board. For optimum cost, the thickness of the aluminum foil should be as thin as possible while still maintaining its integrity. The normal range of thickness utilized to adhere to a strong nail base board is from about 0.0003-inches up to about 0.0070-inches thick. Thinner foils can and have been utilized with some measure of success and of course thicker foils work very well, but increase the cost.

Since aluminum foils can be purchased with different hardness ratings, the particular hardness used will depend more on the properties needed to process the product during manufacturing than upon the properties of the final product. In other words, “Full Hard,” “Half Hard,” and “Full Soft” aluminum foil will all work well in the final product, but will not perform the same in any given manufacturing process.

When used properly, that is with the aluminum facing generally down toward the flat ceiling, this foil prevents up to 97% of the heat energy coming into it from radiating down toward the building's usable interior space. The shiny side of the foil must be installed facing out, and is thereafter protected from foil damage because an inherent advantage of this radiant cross-vented nail base insulative building panel is that once assembled, the aluminum foil is protected.

If the foil can be located next to a layer of quiet, or slowly moving air about ¾-inch thick, the resulting R-value can be measured, and can be substantial; e.g. up to 2.7. Quiet, or slowly moving air is always the best substance to have adjacent to the polished aluminum. While the ¾-inch thick air layer is currently believed to be ideal, other layers, especially thicker layers, will be more effective than any solid materials, such as OSB. The location of the aluminum foil; e.g., what is next to it, plays a role in how effective it is. For the radiant barrier to be effective, it must face an air space. In other words, the layer of aluminum foil has a shiny surface which faces toward the air channels. The angle of the layer is also a variable. Horizontal is better than vertical, and better than any other non-horizontal angles.

The bottom sheet 26 is comprised of a structurally sound plastic foam insulation material. For example, the bottom sheet 26 can be comprised of polyurethane modified polyisocyanurate foam, polyurethane-foam, phenolic-formaldehyde foam, or polystyrene foam. The polystyrene foam can be either the extruded type of foam board, or the expanded type of foam board that is cut from a large block into desired board thicknesses. The bottom sheet 26 preferably has facers provided on both of its broad, flat surfaces. Inclusion of a facer on the sheet 26 enhances application of a construction adhesive to the sheet 26. If polystyrene sheets are used without a protective skin (facer), the choice of construction adhesive is limited to those without a strong organic solvent thinner.

The bottom layer 26 that is made from a structurally sound plastic foam board has, at a 1-inch thickness, an insulative “R-Value” above 3.0. An R-Value at a thickness of 1-inch is defined as the RESISTANCE to thermal conductivity in units of: $\frac{\left(\mathrm{square}\mathrm{feet}\right)\times \left(\mathrm{degrees}F.\right)\times \left(\mathrm{hour}\right)}{\left(\mathrm{British}\mathrm{Thermal}\mathrm{Unit}\left[\mathrm{BTU}\right]\right)}$

Most foam board insulation products used in building construction are thicker than 1-inch; the average actually being slightly over 2-inches. If a foam insulation board has an R-Value of 6.0 at 1-inch, the same product at 2-inches has at least an R-Value of double that; i.e., R=12.0 or higher. As an example, Atlas Roofing Corporation's ACFoam®-II at 2.0-inches is R=12.1.

In one embodiment, the spacer members 24 are secured in place by a construction grade adhesive such as an adhesive of the type known as a subfloor and deck adhesive. Contech's PL-400, H B Fuller's “Sturdibond”, and Macklenburg-Duncan's “MD 400” are examples of appropriate construction grade adhesives when the foam board 26 has facers and/or the spacers 24 are wood or foam board with their own facers. In other embodiments, the spacer members 24 can be secured in place by hot melt gluing techniques, or by mechanical fastening (including broad headed nails and/or staples). It has further been discovered that if the processing is handled carefully, the common white glue (“Elmer's” type) will fasten the EPS vent strips of the preferred embodiment to both the aluminum foil and felt-faced polyisocyanurate, or polystyrene, foam board insulation 26. Care must be taken to not wiggle nor jiggle the assembled radiant-vented nail base panels 10 while the white glue slowly dries.

Thus the panels described herein provide a distinct improvement over prior art ventilating and insulating panels. These improved products allow the benefits of any prior art vented nail base insulation panel product, and also add the measurable benefit of providing a radiant barrier that has been recognized by the USA Department Of Energy (DOE) as a valuable means of conserving energy.

According to some of its aspects, a thermally insulative building construction panel comprises: a first sheet, the first sheet comprising a rigid nail-anchoring material having a density in excess of 25 lbs./cubic foot; a second sheet, the second sheet comprising a layer of aluminum foil that is securely adhered to the first sheet; a third sheet, the third sheet comprising an insulation material having a density less than 5 lbs./cubic foot and having an insulative “R” value in excess of 3.0 per inch thickness; and, a plurality of spacer members connected in fixed positions between the second sheet and the third sheet for defining air channels between the sheets and between the spacer members themselves, the spacer members being (preferably directly) connected to the second sheet and the third sheet for maintaining a spaced parallel relationship between the second sheet and the third sheet.

The top sheet, or rigid nail-anchoring material is preferably comprised of a material selected from the group consisting of plywood, Waferboard, oriented strand board, and particle board. The second sheet is preferably uniformly adhered to the top sheet and is comprised of aluminum foil. The third sheet, or bottom sheet, is preferably comprised of an insulation material selected from the group consisting of polyurethane modified polyisocyanurate foam, polyurethane foam, phenolic-formaldehyde foam, and polystyrene foam. The spacer members are comprised of at least one material selected from the group consisting of solid wood; plywood, Waferboard, oriented strand board, and particle board; polyurethane modified polyisocyanurate foam, polyurethane foam, phenolic-formaldehyde foam, and polystyrene foam; and a prefabricated metal material. The spacer members are preferably at least one-inch thick.

The structural support panel for the waterproofing membrane as herein described also provides a high level of thermal insulation, protecting the interior temperature from the wide changes in outside temperatures, as well as protection from the sun's radiant energy. In this regard, the small up-front charge for aluminum foil adhered to the nail-base panel is expected to pay for itself with lower heating or air conditioner costs.

Other advantages herein provided are provision of an insulative building panel that (1) allows air to move in all directions; (2) utilizes scrap plastic foam for spacer material, thus improving the R-Value at the spacer locations and saving some plastic waste from expensive land-fills; and (3) utilizes the unique emissivity properties of aluminum.

Another substantial advantage of the embodiments herein described and modifications thereof is that (4) the aluminum foil is protected from damage caused by jobsite collisions during handling and installation.

Two other advantages of the embodiments herein described and modifications thereof are (5) the provision of an insulative building panel which can reduce the number of spacer members required along any given dimension; and, (6) the provision of an insulation panel with better thermal resistance per equal thickness when compared to prior art panels.

Yet another advantage of the embodiments herein described and modifications thereof is (7) the ability to make insulative building panels having an essentially unlimited range of cross-ventilation in two dimensions while maintaining compressive load and strength requirements.

While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements.

Claims

1. A thermally insulative building construction panel comprising:

a first sheet comprising a rigid nail-anchoring material;

a second sheet comprising a layer of aluminum foil that is securely adhered to the first sheet;

a third sheet comprising an insulation material;

plural discrete spacer members connected in fixed positions between the second sheet and the third sheet for defining air channels between the sheets and between the spacer members themselves, the plural discrete spacer members being arranged in a pattern to permit multi-dimensional air flow substantially throughout the panel, the pattern being such that, for the discrete spacer members arranged in an any direction of alignment, an air channel extends perpendicular to the direction of alignment.

2. The panel of claim 1, wherein the layer of aluminum foil has a shiny surface which faces toward the air channels.

3. The panel of claim 1, wherein the first sheet has a density in excess of 25 pounds/cubic foot and the third sheet has a density less than 5 pounds/cubic foot and having an insulative “R” value in excess of 3.0 per inch thickness.

4. The panel of claim 1, wherein the first sheet comprises of a material selected from the group consisting of plywood, Waferboard, oriented strand board, and particle board.

5. The panel of claim 1, wherein the second sheet is uniformly adhered to the top sheet.

6. The panel of claim 1, wherein the third sheet is comprised of an insulation material selected from the group consisting of polyurethane modified polyisocyanurate foam, polyurethane foam, phenolic-formaldehyde foam, and polystyrene foam.

7. The panel of claim 1, wherein the spacer members are comprised of at least one material selected from the group consisting of solid wood, the materials of claim 2, the materials of claim 4, and a prefabricated metal material.

8. The panel of claim 1, wherein the spacer members are at least one-inch thick.

9. The panel of claim 1, wherein the spacer members are arranged in a rectangular matrix.

10. The panel of claim 1, wherein the spacer members are set back from along one or more edges of the panel.

11. The panel of claim 1, wherein the first sheet has a smaller surface area than the third sheet to facilitate formation of an expansion gap between adjacent panels.

12. A thermally insulative building construction panel comprising:

a first sheet comprising a rigid nail-anchoring material;

a second sheet comprising a layer of aluminum foil that is securely adhered to the first sheet;

a third sheet comprising an insulation material;

plural spacer members connected in fixed positions between the second sheet and the third sheet for defining air channels between the sheets and between the spacer members themselves, the plural spacer members being configured to permit multi-dimensional air flow substantially throughout the panel, the plural spacer members having a surface thereof formed in a square wave shape with alternating crests and troughs which essentially repeat along a major dimension of the spacer member.

13. The panel of claim 12, wherein the first sheet has a density in excess of 25 pounds/cubic foot and the third sheet has a density less than 5 pounds/cubic foot and having an insulative “R” value in excess of 3.0 per inch thickness.

14. The panel of claim 12, wherein the first sheet comprises of a material selected from the group consisting of plywood, Waferboard, oriented strand board, and particle board.

15. The panel of claim 12, wherein the second sheet is uniformly adhered to the top sheet.

16. The panel of claim 12, wherein the third sheet is comprised of an insulation material selected from the group consisting of polyurethane modified polyisocyanurate foam, polyurethane foam, phenolic-formaldehyde foam, and polystyrene foam.

17. The panel of claim 12, wherein the spacer members are comprised of at least one material selected from the group consisting of solid wood, the materials of claim 2, the materials of claim 4, and a prefabricated metal material.

18. The panel of claim 12, wherein the spacer members are at least one-inch thick.

19. The panel of claim 12, wherein the first sheet has a smaller surface area than the third sheet to facilitate formation of an expansion gap between adjacent panels.

20. The panel of claim 12, wherein each trough extends to a depth of approximately one half the thickness of the spacer member to define one of the air channels through the spacer member in a length direction of the panel.

21. The panel of claim 12, wherein the crests and troughs have essentially a same periodicity or length along a width dimension of the panel, except for two extreme-most crests and troughs at each end thereof.

22. The panel of claim 12, wherein the layer of aluminum foil has a shiny surface which faces toward the air channels.