INSULATING PANELS

Abstract

In some embodiments, a method and/or system may include a construction panel system. The construction panel system may include a first panel, a second panel, and a plurality of spacers. In some embodiments, the second panel positioned may be substantially parallel to the first panel. The plurality of spacers may be positioned between the first panel and the second panel. The spacers may allow fluids to pass around the spacers and between the first and second panels. In some embodiments, the spacers may be substantially aligned in a first direction and unaligned in at least a second direction. The first direction may be different than the second direction. In some embodiments, a plurality of openings may extend through the second panel. At least some of the plurality of openings may allow fluids to pass through the openings and in a space between the first and second panels.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present disclosure generally relates to producing and using insulated construction panels. More particularly, the disclosure generally relates to systems and methods for producing and using structurally stable insulated panels.

2. Description of the Relevant Art

The roofs and walls of structures must deal with various environmental and interior building factors such as heat insulation, proper venting and/or moisture control. The design of the roof and wall systems needs to be structurally sound while providing for a habitable temperature living space. There are three sources of heat that affect the ability of a building structure's insulation to control heat transfer including convective heat transfer, conductive heat transfer, and radiant heat. Currently, there is not a manufactured insulation and venting assembly that: has an air space that can be used for air and moisture venting; appropriately arranged spacers between a first and a second sheet.

SUMMARY

In some embodiments, a system may include a construction panel system. The construction panel system may include a first panel, a second panel, and a plurality of spacers. In some embodiments, the second panel may be positioned substantially parallel to the first panel. The plurality of spacers may be positioned between the first panel and the second panel. A first surface of the spacers may be coupled to a first surface of the first panel. A second surface of the spacers substantially opposite to the first surface may be coupled to a first surface of the second panel. The spacers may allow fluids (e.g., air, gases, water, etc.) to pass around the spacers and between the first and second panels. In some embodiments, the spacers may be substantially aligned in a first direction and unaligned in at least a second direction. The first direction may be different than the second direction. In some embodiments, a plurality of openings may extend through the second panel. At least some of the plurality of openings may allow fluids to pass through the openings and in a space between the first and second panels.

In some embodiments, the construction panel system may include more than two panels (e.g., three, four, etc.). Construction panel systems with more than two panels may have two or more channels as appropriate depending upon the number of panels (e.g., with three panels there may be a first set of spacers between the first and second panels and a second set of spacers between the second and third set of panels). In some embodiments, the plurality of openings may extend through at least some of the plurality of panels into as many spaces between the panels as exist

In some embodiments, at least a portion of the first panel, at least a portion the second panel, and/or at least a portion the plurality of spacers may include wood.

In some embodiments, at least a portion of the first panel, at least a portion the second panel, and/or at least a portion the plurality of spacers may include oriented strand board. In some embodiments, at least a portion of the construction panel (e.g., at least some of the spacers) may be formed from a material that inhibits the conduction of heat (e.g., plastics).

In some embodiments, the system may include indicia_[B1]. The indicia may be positioned on an exterior surface of the first and/or second panel. The indicia may be configured to designate where the spacers are positioned.

In some embodiments, the system may include a radiant barrier. The radiant barrier may be applied to at least one surface of the first and/or second panel. In some embodiments, the radiant barrier may be applied to at least a portion of the area between the spacers. In some embodiments, the radiant barrier may be applied to at least the first surface of the first panel.

In some embodiments, the construction panel system may be coupled to a roofing framework system.

In some embodiments, a method may include insulating a building construct. A method of insulating a building construct may include coupling a construction panel system to a framework of a building. The construction panel system may be as described herein. The method may include conveying fluids through a plurality of openings extending through the second panel and through a space between the first and second panels and between the spacers.

In some embodiments, the method may include coupling a second construction panel system to the framework of the building adjacent the installed construction panel system such that the spacers of the second construction panel system are substantially aligned with the spacer of the installed construction panel system in the first direction. The method may include conveying fluids through the plurality of openings of the installed construction panel system and through the second construction panel system.

BRIEF DESCRIPTION OF THE DRAWINGS

Advantages of the present invention may become apparent to those skilled in the art with the benefit of the following detailed description of the preferred embodiments and upon reference to the accompanying drawings.

FIG. 1 depicts a diagram of an embodiment of a construction panel system with one of the panels removed.

FIG. 2 depicts a diagram of a crosscut view of an embodiment of a construction panel system.

FIGS. 3A-C depict diagrams of a bottom view of an embodiment of a construction panel system.

FIG. 4 depicts a diagram of a top view of an embodiment of a construction panel system.

FIG. 5 depicts a diagram of a perspective view of an embodiment of a construction panel system installed in a building.

FIG. 6 depicts a diagram of a cross cut view of an embodiment of a construction panel system installed in a building.

While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and may herein be described in detail. The drawings may not be to scale. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.

The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description. As used throughout this application, the word “may” is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). The words “include,” “including,” and “includes” indicate open-ended relationships and therefore mean including, but not limited to. Similarly, the words “have,” “having,” and “has” also indicated open-ended relationships, and thus mean having, but not limited to. The terms “first,” “second,” “third,” and so forth as used herein are used as labels for nouns that they precede, and do not imply any type of ordering (e.g., spatial, temporal, logical, etc.) unless such an ordering is otherwise explicitly indicated. For example, a “third die electrically connected to the module substrate” does not preclude scenarios in which a “fourth die electrically connected to the module substrate” is connected prior to the third die, unless otherwise specified. Similarly, a “second” feature does not require that a “first” feature be implemented prior to the “second” feature, unless otherwise specified.

Various components may be described as “configured to” perform a task or tasks. In such contexts, “configured to” is a broad recitation generally meaning “having structure that” performs the task or tasks during operation. As such, the component can be configured to perform the task even when the component is not currently performing that task (e.g., a set of electrical conductors may be configured to electrically connect a module to another module, even when the two modules are not connected). In some contexts, “configured to” may be a broad recitation of structure generally meaning “having circuitry that” performs the task or tasks during operation. As such, the component can be configured to perform the task even when the component is not currently on. In general, the circuitry that forms the structure corresponding to “configured to” may include hardware circuits.

Various components may be described as performing a task or tasks, for convenience in the description. Such descriptions should be interpreted as including the phrase “configured to.” Reciting a component that is configured to perform one or more tasks is expressly intended not to invoke 35 U.S.C. §112, paragraph six, interpretation for that component.

The scope of the present disclosure includes any feature or combination of features disclosed herein (either explicitly or implicitly), or any generalization thereof, whether or not it mitigates any or all of the problems addressed herein. Accordingly, new claims may be formulated during prosecution of this application (or an application claiming priority thereto) to any such combination of features. In particular, with reference to the appended claims, features from dependent claims may be combined with those of the independent claims and features from respective independent claims may be combined in any appropriate manner and not merely in the specific combinations enumerated in the appended claims.

It is to be understood the present invention is not limited to particular devices or biological systems, which may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting. As used in this specification and the appended claims, the singular forms “a”, “an”, and “the” include singular and plural referents unless the content clearly dictates otherwise. Thus, for example, reference to “a linker” includes one or more linkers.

DETAILED DESCRIPTION

Definitions

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art.

The term “connected” as used herein generally refers to pieces which may be joined or linked together.

The term “coupled” as used herein generally refers to pieces which may be used operatively with each other, or joined or linked together, with or without one or more intervening members.

The term “directly” as used herein generally refers to one structure in physical contact with another structure, or, when used in reference to a procedure, means that one process effects another process or structure without the involvement of an intermediate step or component.

The term “radiant barrier” as used herein generally refers to reflective barriers which inhibit heat transfer by thermal radiation.

In some embodiments, a system may include a construction panel system. A construction panel system 100 may include a first panel 110, a second panel 120, and a plurality of spacers 130. FIG. 1 depicts a diagram of an embodiment of construction panel system 100 with second panel 120 removed. FIG. 2 depicts a diagram of a crosscut view of an embodiment of construction panel system 100. In some embodiments, the second panel may be positioned substantially parallel to the first panel. The second panel may be positioned substantially parallel to the first panel within the parameters commonly associated with the construction materials used to form the system and the construction methods used to assemble the system. In some embodiments, the first and second panel may not be positioned parallel to one another. The first and second panel may be positioned at an angle to one another.

The plurality of spacers may be positioned between the first panel and the second panel. A first surface 140 of spacers 130 may be coupled to a first surface 150 of first panel 110. A second surface 160 of spacers 130 substantially opposite to first surface 150 may be coupled to a first surface 170 of second panel 120. The spacers may be coupled to the first and/or second panel using one or more adhesives. The spacers may be coupled to the first and/or second panel using one or more fasteners. In some embodiments, the spacer may be formed as part of the first and/or second panel during manufacture.

In some embodiments, the spacers are positioned between the first and second panel such that there are unobstructed channels formed between the spacers from at least one end of the system to at least a second end of the panel system. The spacers may allow fluids to pass around the spacers and between the first and second panels. Fluids may include liquids (e.g., water) and/or gases (e.g., air, water vapor, etc.).

FIGS. 3A-C depicts a diagram of a bottom view of an embodiment of a construction panel system 100. In some embodiments, a plurality of openings 180 may extend through second panel 120 (e.g., as depicted in FIG. 3A). At least some of the plurality of openings may allow fluids to pass through the openings and in a space between the first and second panels. In some embodiments, fluids conveyed through the openings and between the first and second panels function as insulation, increasing the insulation properties of the construction panel system. Air is a very good insulator. Gasses like air do no transfer heat very well because the molecules are so far apart from each other. Movement of gases (e.g., air) may allow air to transfer heat because the air molecules carry the energy as they move. During use, some construction panels may have a plurality of openings as described while others may not have the plurality of openings (e.g., as depicted in FIG. 3B). In some embodiments, a plurality of construction panels may be installed in series such that fluids may be conveyed through a plurality of openings in the first panel then through the channels of a first panel to a second panel. The fluids once in the second panel may continue on through channels in the second panel into an adjacent third panel and/or out of the second panel's channels and directed out of a building or towards a ventilation system. In some embodiments, a starter strip (e.g., as depicted in FIG. 3C) may be used which is of a smaller dimension which includes the plurality of openings discussed which during installation couples to another construction panel such that air moves through the plurality of openings of the starter strip and into the channels of the other coupled construction panel. In some embodiments, at least some of the openings may be pitched at an angle relative to the second panel. Angled openings may allow fluids to be more easily conveyed through the second panel (e.g., from the soffit) into the airspace.

In some embodiments, the construction panel system may include more than two panels (e.g., three, four, etc.). Construction panel systems with more than two panels may have two or more channels as appropriate depending upon the number of panels (e.g., with three panels there may be a first set of spacers between the first and second panels and a second set of spacers between the second and third set of panels). In some embodiments, the plurality of openings may extend through at least some of the plurality of panels into as many spaces between the panels as exist

In some embodiments, the spacers may be substantially aligned in a first direction and unaligned in at least a second direction. The first direction may be different than the second direction. The spacers may be positioned such that adjacent rows of spacers are unaligned in a first direction. The spacers may be positioned such that adjacent rows of spacers are unaligned in a second direction. The second direction may be substantially perpendicular to the first direction. Misaligning the spacers may provide structural stability to the system. Structural stability may be provided especially when installers or others are walking on the system during and/or after installation, for example, on a building. Setting the spacers in such a pattern (e.g., as depicted in FIG. 4) may inhibit closing off of fluid channels through the system (e.g., when fasteners are inadvertently installed incorrectly or when installing roofing shingles or other roofing materials). The spacer layout may allow for installation of vent pipes, skylights, windows etc without substantially restricting the flow of fluids.

FIG. 4 depicts a diagram of a top view of an embodiment of a construction panel system 100. In some embodiments, the system may include indicia 190. The indicia may be positioned on an exterior surface of the first and/or second panel. The indicia may be configured to designate where the spacers are positioned. In some embodiments, the indicia may be positioned on an exterior surface of the first panel. The exterior surface of the first panel may be viewable to a tradesman during installation of the system, for example, as sheathing on a roof.

The indicia may allow an installer to know where the spacers are located between the first and second panels. The installer may then position fasteners to couple the system to a structure such that the fasteners penetrate through the spacers. A first advantage of installing fasteners through the spacers may be providing a more structurally stable installed system. Fasteners installed in other areas where spacers are not positioned may disrupt the structural integrity of the first panel, due to the force at which fasteners are installed with. In some instances the fastener may not disrupt the first panel structurally or in addition to disruption the fastener may press the first panel and the second panel together eliminating the space in between the two panels. “Pinching” the two panels together and eliminating the space between the two panels naturally restricts the air flow between the two panels reducing the insulating value of the system.

In some embodiments, the system may include a radiant barrier. The radiant barrier may be applied to at least one surface of the first and/or second panel. In some embodiments, the radiant barrier may be applied to at least a portion of the area between the spacers. The radiant barrier may be applied to the area between the spacers such that the radiant barrier does not inhibit coupling of the spacers to the panels. Adhesives may be used to couple the spacers to the panels and at least some radiant barriers may inhibit the adhesives from coupling the spacer to the panel. Radiant barriers positioned between the spacers and the panels may better conduct heat through the panels as opposed to reflecting the heat as desired.

In some embodiments, the radiant barrier may be applied to at least the first surface of the first panel. Applying the radiant barrier to the first surface of the first panel may provide the necessary air gap required next to the radiant barrier while reflecting the most radiant heat before it penetrates any further through the system.

In some embodiments, at least a portion of the first panel, at least a portion the second panel, and/or at least a portion the plurality of spacers may include wood. In some embodiments, at least a portion of the construction panel (e.g., at least some of the spacers) may be formed from a material that inhibits the conduction of heat (e.g., plastics). The system may be formed at least in part from wood. The system may be formed at least in part by adhesives. In some embodiments, at least a portion of the first panel, at least a portion the second panel, and/or at least a portion the plurality of spacers may include oriented strand board (OSB). The construction panels may be formed in any shape or to any appropriate dimensions. In some embodiments, construction panels may be formed in dimensions mimicking standard industry standards (e.g., four foot by eight foot) to facilitate installation. The panels and spacers may be formed using different dimensions. The first and/or second panel_[B2] may be ⅛″ to 3″ thick, ¼″ to 1″ thick, or about ¼″ thick. The spacers may be ⅛″ to 3″ thick, ¼″ to 1″ thick, or about ¼″ thick. The spacers may have a circular shape. The spacers may have a shape comprising an oval, a square, a diamond, a hexagon, etc. The spacers may have a width/diameter which is 0.5″ to 12″, 1″ to 3″, or about 2″.

In some embodiments, a method may include insulating a building construct. A method of insulating a building construct may include coupling a construction panel system to a framework of a building. The construction panel system may be as described herein. The method may include conveying fluids through a plurality of openings extending through the second panel and through a space between the first and second panels and between the spacers.

In some embodiments, the construction panel system may be coupled to a roofing framework system. FIG. 5 depicts a diagram of a perspective view of an embodiment of construction panel system 100 installed in a building 200. FIG. 6 depicts a diagram of a cross cut view of an embodiment of a construction panel system installed in a building. The embodiment in FIGS. 5-6 depicts construction panels 100 installed in a structure as roof sheathing; however, this should not been as a limiting example. The construction panels may be used in other ways, shapes or fashions (e.g., as siding on a building). The panels may be installed such that channels from adjoining panels are substantially aligned to facilitate fluid flow between the panels. Clips (e.g., H-clips) may be used to ensure the panels stay properly aligned during and after installation. Any type of roofing material may be installed over the construction panel system. In the embodiment depicted in FIGS. 5-6 asphalt shingles 210 may be installed over the construction panels. FIG. 5 depicts multiple construction panels 100a-d installed as roof sheathing. Fasteners may be used to couple the construction panels to the framing of the building. The fasteners may be installed through the spacer 130 using indicia 190 to locate the spacers.

In some embodiments, the method may include coupling a second construction panel system to the framework of the building adjacent the installed construction panel system such that the spacers of the second construction panel system are substantially aligned with the spacer of the installed construction panel system in the first direction. The method may include conveying fluids through the plurality of openings of the installed construction panel system and through the second construction panel system.

In some embodiments, air 220 may flow through soffit 230 (depicted in FIG. 6) and then through plurality of openings 180. Once air 220 has been conveyed through openings 180, the air may travel between first panel 110 and second panel 120 between spacers 130 of construction panel 100a (as depicted in FIG. 5). Air 220 may then convey through construction panel 100a and on into construction panels 100c and 100d. Air 220 may then be conveyed out of the attic through, for example, ridge vent 240. Air 220 may function as an insulator. The system may allow heat/moisture in the attic to vent out as normal. Air enters thru the soffit and is able to enter the air gap between the two panels, the openings in the construction panel, and/or the attic.

EXAMPLES

An experiment was conducted in order to ascertain the effectiveness of an embodiment of the constructions panel system. In the experiment a mock reduced scale building attic was constructed with the attic divided into two portions. On a first side of the attic embodiments of the herein described construction panels were installed while on the other side of the attic radiant barrier sheathing (i.e., LP Building Products TechShield) was installed. Several temperature gauges were installed to monitor the temperature of various areas of the mock enclosure which are summarized in TABLE I below. The construction panels used in the experiment included a radiant barrier on the inside surface of the outer panel. As can be seen in the results in TABLE 1 the construction panel system showed a dramatic decrease in the temperature in the attic verses the attic temperature in the attic with the radiant barrier sheathing.

TABLE 1
		air gap in	Construction
		construction	panel attic	Tec shield	Notes
	outside	panel	space	attic space	concerning
time	temp	temp	temp	temp	weather
11:00	80 F.	90 F.	75 F.	115 F.	Cloudy
11:30	85 F.	95 F.	75 F.	120 F.	Sunny
12:00	90 F.	100 F.	80 F.	125 F.	Sunny
12:30	90 F.	100 F.	80 F.	125 F.	Sunny
1:00	90 F.	100 F.	+80 F.	125 F.	Sunny
1:30	90 F.	100 F.	+80 F.	125 F.	Sunny
2:00	+90 F.	100 F.	85 F.	+125 F.	Sunny
2:30	+90 F.	100 F.	85 F.	+125 F.	Sunny
3:00	95 F.	105 F.	90 F.	130 F.	Sunny
3:30	95 F.	110 F.	90 F.	130 F.	Sunny
4:00	+95 F.	105 F.	90 F.	130 F.	Cloudy

In this patent, certain U.S. patents, U.S. patent applications, and other materials (e.g., articles) have been incorporated by reference. The text of such U.S. patents, U.S. patent applications, and other materials is, however, only incorporated by reference to the extent that no conflict exists between such text and the other statements and drawings set forth herein. In the event of such conflict, then any such conflicting text in such incorporated by reference U.S. patents, U.S. patent applications, and other materials is specifically not incorporated by reference in this patent.

Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the general manner of carrying out the invention. It is to be understood that the forms of the invention shown and described herein are to be taken as the presently preferred embodiments. Elements and materials may be substituted for those illustrated and described herein, parts and processes may be reversed, and certain features of the invention may be utilized independently, all as would be apparent to one skilled in the art after having the benefit of this description of the invention. Changes may be made in the elements described herein without departing from the spirit and scope of the invention as described in the following claims.

Claims

1. A construction panel system, comprising:

a first panel;

a second panel positioned substantially parallel to the first panel;

a plurality of spacers positioned between the first panel and the second panel, wherein a first surface of the spacers is coupled to a first surface of the first panel, wherein a second surface of the spacers substantially opposite to the first surface is coupled to a first surface of the second panel, wherein the spacers allow fluids to pass between the spacers and the first and second panels, wherein the spacers are substantially aligned in a first direction and unaligned in at least a second direction, and wherein the first direction is different than the second direction; and

a plurality of openings extending through the second panel allowing fluids to pass through the openings and in a space between the first and second panels.

2. The system of claim 1, wherein at least a portion of the first panel, at least a portion the second panel, and/or at least a portion the plurality of spacers comprise wood.

3. The system of claim 1, wherein at least a portion of the first panel, at least a portion the second panel, and/or at least a portion the plurality of spacers comprise oriented strand board, plywood, or non-wood materials.

4. The system of claim 1, further comprising indicia positioned on an exterior surface of the first and/or second panel, wherein the indicia are configured to designate where the spacers are positioned.

5. The system of claim 1, further comprising a radiant barrier applied to at least one surface of the first and/or second panel.

6. The system of claim 1, further comprising a radiant barrier applied to at least one surface of the first and/or second panel, wherein the radiant barrier is applied to at least a portion of the area between the spacers.

7. The system of claim 1, further comprising a radiant barrier applied to at least the first surface of the first panel.

8. The system of claim 1, further comprising a radiant barrier applied to at least the first surface of the first panel, wherein the radiant barrier is applied to the first surface in at least a portion of the area between the spacers.

9. The system of claim 1, wherein the construction panel system is coupled to a roofing framework system.

10. A method of insulating a building construct, comprising:

coupling a construction panel system to a framework of a building, wherein the construction panel system comprises: a first panel; a second panel positioned substantially parallel to the first panel; a plurality of spacers positioned between the first panel and the second panel, wherein a first surface of the spacers is coupled to a first surface of the first panel, wherein a second surface of the spacers substantially opposite to the first surface is coupled to a first surface of the second panel, wherein the spacers are substantially aligned in a first direction and unaligned in at least a second direction, and wherein the first direction is different than the second direction;

conveying fluids through a plurality of openings extending through the second panel and through a space between the first and second panels and between the spacers.

11. (canceled)

12. The method of claim 10, wherein at least a portion of the first panel, at least a portion the second panel, and/or at least a portion the plurality of spacers comprise oriented strand board, plywood, or non-wood materials.

13. The method of claim 10, wherein said coupling the construction panel system to a framework comprises installing fasteners through indicia positioned on an exterior surface of the first and/or second panel, wherein the indicia designate, during use, where at least some of the spacers are positioned.

14. The method of claim 10, further comprising reflecting thermal radiation using a radiant barrier applied to at least one surface of the first and/or second panel.

15. The method of claim 10, further comprising reflecting thermal radiation using a radiant barrier applied to at least one surface of the first and/or second panel, wherein the radiant barrier is applied to at least a portion of the area between the spacers.

16. The method of claim 10, further comprising reflecting thermal radiation using a radiant barrier applied to at least the first surface of the first panel.

17. The method of claim 10, further comprising reflecting thermal radiation using a radiant barrier applied to at least the first surface of the first panel, wherein the radiant barrier is applied to the first surface in at least a portion of the area between the spacers.

18. The method of claim 10, further comprising:

coupling a second construction panel system to the framework of the building adjacent the installed construction panel system such that the spacers of the second construction panel system are substantially aligned with the spacer of the installed construction panel system in the first direction; and

conveying fluids through the plurality of openings of the installed construction panel system and through the second construction panel system.

19. The method of claim 10, wherein said coupling the construction panel system to the framework comprises coupling the construction panel system to a roofing framework system.

20. The system of claim 1, wherein a first surface of the spacers is coupled directly to a first surface of the first panel using an adhesive, wherein a second surface of the spacers substantially opposite to the first surface is coupled directly to a first surface of the second panel using an adhesive.

21. The system of claim 1, wherein the plurality of openings extending through the second panel allows air to pass through the openings and in a space between the first and second panels such that the air functions as an insulator.