Insulation panel for use in building construction.

Abstract

A panel useful as a roof deck material (and optional insulating material, and optional moisture barrier) for a roof of a building or as a wall material for a wall of a building comprises a plurality of side members comprising at least a first side member, a second side member, and a third side member. A void capable of receiving an insulating material exists between at least the first side member, the second side member, and the third side member. The panel also comprises a plurality of stiffeners comprising at least a first stiffener spanning a first distance between at least two side members of the plurality of side members.

Description

CROSS REFERENCES AND PRIORITIES

This application claims priority to U.S. Provisional Application No. 63/235,645 filed on 20 Aug. 2022 the teachings of which are incorporated by reference herein in their entirety.

BACKGROUND

Building roofs, particularly flat or low sloped roofs, commonly include at least four components. First is the roof frame which is commonly constructed of studs made of wood, metal or the like attached to similar wall studs. Second is the roof deck which is commonly constructed of a rigid planar material such as metal which is fastened to the roof frame. Next is an insulating material which is applied on top of the roof deck to slow the transfer Of heat through the building roof and reduce heat loss and gain. Finally, a membrane which is commonly applied on top of the insulating material as a waterproofing measure. In some roofs a ballasting material such as stone or gravel may be applied over the membrane to assist in holding the membrane in place. Instead of—or in addition to—ballasting material, some roofs may include an adhesive and/or a fastener which assists in holding the roofing components in place.

Commonly roof deck materials come in large sheets of metal with corrugated aluminum being the most common material used for roof decking. Sheets of the roof decking are lifted to the top of the building and fastened to the roof frame by manual laborers. Only after the sheets of roof decking have been installed can the laborers install the insulating material, membrane, and optional ballasting material.

In practice, the sheets of metal used for roof decking are difficult to install as they require precision handling with large equipment such as industrial cranes—often involving a multitude of manual laborers—to accurately position the large heavy sheets of metal. These sheets of metal typically weigh between two and four pounds per square foot and therefore require the designers and architects to increase the bulk of steel in the roof's vertical support members. Further, the metal sheets are limited to smaller spans—typically in the range of between three and four feet—due to the inherent tensile strength of the metals relative to their thickness.

The common practice—necessitated by the nearly zero R-Value (insulative quality) of the sheet metal construction of the roof deck—of installing insulating material only after installation of the roof deck also adds additional cost and labor time to the roof installation and repair process. Yet another step is often required to add a moisture membrane to the outer surface of the insulating material to prevent moisture from entering the structure and decaying the insulating material, roof deck material, and/or material of the roof support members.

Additionally, the sheets of metal are often subject to damage by high winds (such as those encountered in hurricanes or tornadoes) which move around the building and under the roof surface. In extreme circumstances the entire roof deck can be dislodged from the building leading to catastrophic damage.

Finally, the sheets of metal used in prior art roof decks are prone to rusting. This can result in the roof deck becoming structurally unsound over time. In some prior art embodiments, expensive and often environmentally damaging coatings have been applied to the sheets of metal. However, such coatings have been found to only delay—not prevent—deterioration of the sheets of metal due to rust.

The need exists, therefore, for an improved apparatus which may be used for roof decking.

SUMMARY

It is described herein a panel. The panel comprises a plurality of side members, a void, and a plurality of stiffeners. The plurality of side members comprises at least a first side member, a second side member, and a third side member. The void is located between at least the first side member, the second side member, and the third side member and is capable of receiving an insulating material. The plurality of stiffeners comprises at least a first stiffener spanning a first distance between at least two side members of the plurality of side members.

In some embodiments, the plurality of side members may further comprise at least a fourth side member.

In certain embodiments, at least one of the side members of the plurality of side members may have an “I” shaped cross-sectional profile. In some embodiments, at least one of the side members of the plurality of side members may have an “L” shaped cross-sectional profile. In certain embodiments, at least one of the side members of the plurality of side members may have a “T” shaped cross-sectional profile.

In some embodiments, the plurality of stiffeners may further comprise at least a second stiffener. When present, the second stiffener may span a second distance between at least two side members of the plurality of side members or between one side member of the plurality of side members and the first stiffener.

In certain embodiments, the plurality of stiffeners may further comprise at least a third stiffener. When present, the third stiffener may span a third distance between at least two side members of the plurality of side member, or between one side member of the plurality of side members and one other stiffener of the plurality of stiffeners, or between two other stiffeners of the plurality of stiffeners.

In some embodiments, the plurality of stiffeners may further comprise at least a fourth stiffener. When present, the fourth stiffener may span a fourth distance between at least two side members of the plurality of side member, or between one side member of the plurality of side members and one other stiffener of the plurality of stiffeners, or between two other stiffeners of the plurality of stiffeners.

In certain embodiments, the plurality of stiffeners may further comprise at least a fifth stiffener. When present, the fifth stiffener may span a fifth distance between at least two side members of the plurality of side member, or between one side member of the plurality of side members and one other stiffener of the plurality of stiffeners, or between two other stiffeners of the plurality of stiffeners.

In some embodiments, the plurality of stiffeners may further comprise at least a sixth stiffener. When present, the sixth stiffener may span a sixth distance between at least two side members of the plurality of side member, or between one side member of the plurality of side members and one other stiffener of the plurality of stiffeners, or between two other stiffeners of the plurality of stiffeners.

In certain embodiments, at least one of the stiffeners of the plurality of stiffeners may have an “I” shaped cross-sectional profile. In some embodiments, at least one of the stiffeners of the plurality of stiffeners may have an “L” shaped cross-sectional profile. In certain embodiments, at least one of the stiffeners of the plurality of stiffeners may have a “T” shaped cross-sectional profile.

In some embodiments, an intersection point between at least two stiffeners of the plurality of stiffeners may comprise a port.

In certain embodiments, the panel may further comprise the insulating material. When present, the insulating material may have an R-Value selected from the group consisting of at least R-5, at least R-15, at least R-25, at least R-35, at least R-40, at least R-45, at least R-50, and at least R-55. In some embodiments, the insulating material may comprise a first layer of insulation.

In other embodiments, the insulating material may comprise at least a first layer of insulation, a second layer of insulation, and a third layer of insulation. In such embodiments, the second layer of insulation may be located between the first layer of insulation and the third layer of insulation. In some such embodiments, the second layer of insulation may comprise a phase change material. When present, the phase change material may be selected from the group consisting of paraffin, calcium chloride hexahydrate, sodium sulfate, and Glauber's salt.

In some embodiments, at least one side member of the plurality of side members may comprise an attachment mechanism configured to connect the panel to an adjoining panel.

In certain embodiments, the panel may be a roofing panel configured to be installed on a roof. In other embodiments, the panel may be a wall panel configured to be installed in a wall.

BRIEF DESCRIPTION OF FIGURES

FIG. 1 is a perspective view of one embodiment of a panel without an insulating material.

FIG. 2 is a perspective view of one embodiment of a panel with an insulating material.

FIG. 3 is a cross section of one embodiment of a panel with a single layer of insulating material.

FIG. 4 is a cross section of one embodiment of a panel with three layers of insulating material.

FIG. 5 is a perspective view of a portion of a roof of a structure having a plurality of panels installed therein.

FIG. 6 is a perspective view of a portion of a roof of a structure having a plurality of panels and a membrane cover installed therein.

FIG. 7 is a perspective view of a portion of a wall of a structure having a plurality of panels installed therein.

DETAILED DESCRIPTION

Disclosed herein is a panel which in some embodiments may be used as a roof deck of a roof of a building or as a portion of a wall of a building. The panel is described below with reference to the Figures. As described herein and in the claims, the following numbers refer to the following structures as noted in the Figures.

• 10 refers to a roof.
• 12 refers to a roof deck.
• 15 refers to a membrane.
• 17 refers to a connector.
• 50 refers to a wall.
• 55 refers to a stud.
• 100 refers to a panel.
• 110 refers to a first side member.
• 120 refers to a second side member.
• 130 refers to a third side member.
• 135 refers to a third side member height.
• 140 refers to a fourth side member.
• 150 refers to a void.
• 161 refers to a first stiffener.
• 162 refers to a second stiffener.
• 163 refers to a third stiffener.
• 164 refers to a fourth stiffener.
• 165 refers to a fifth stiffener.
• 166 refers to a sixth stiffener.
• 170 refers to a port.
• 200 refers to an insulating material.
• 210 refers to a first layer of insulation.
• 220 refers to a second layer of insulation.
• 230 refers to a third layer of insulation.

FIG. 1 depicts a perspective view of a panel (100). As shown in FIG. 1, the panel may comprise a plurality of side members forming a polygonal shape. The panel will also comprise a void (150) between the plurality of side members. The void will be capable of receiving an insulating material (200 as shown in FIG. 2). The panel will also comprise a plurality of stiffeners.

The plurality of side members will comprise at least a first side member (110), a second side member (120), and a third side member (130) forming a triangular shape. In the embodiment shown in FIG. 1, the plurality of side members also comprises a fourth side member (140) forming a quadrilateral shape. Common quadrilateral shapes include a square (with dimensions of 4 feet by 4 feet being preferred) and a rectangle (with dimensions of 4 feet by 8 feet being preferred). While a triangular or quadrilateral shape is preferred, embodiments may exist having other shapes including a pentagonal shape (in which case the plurality of side members will further comprise a fifth side member), a hexagonal shape (in which case the plurality of side members will further comprise a fifth side member and a sixth side member), and an octagonal shape (in which case the plurality of side members will further comprise a fifth side member, a sixth side member, a seventh side member, and an eighth side member).

The void (150) will be bounded by at least the plurality of side members. Additionally, the void may be divided into a plurality of smaller voids by the plurality of stiffeners. In this regard, the plurality of stiffeners will comprise at least a first stiffener (161) spanning a first distance between at least two side members of the plurality of side members as shown in FIG. 1. The first stiffener therefore divides the void into two smaller voids, which may be referred to as a first void and a second void.

While FIG. 1 and FIG. 2 shows the void (150) as a hole passing through the panel (100) (i.e. —a through hole), other embodiments may exist. For example, in some embodiments, the void may be a hole which originates at one horizontal surface of the panel, but does not extend all the way through the opposing surface of the panel (i.e. —a blind hole).

In some embodiments, the plurality of stiffeners may further comprise at least a second stiffener (162) as shown in FIG. 1. When present, the second stiffener will span a second distance. In some embodiments, the second distance may be between at least two side members of the plurality of side members as shown in FIG. 1. In some such embodiments, the second distance may intersect one or more other stiffeners of the plurality of stiffeners. In other embodiments, the second distance may be between one side member of the plurality of side members and the first stiffener.

The plurality of stiffeners may also comprise at least a third stiffener (163) as shown in FIG. 1. When present, the third stiffener will span a third distance. In some embodiments, the third distance may be between at least two side members of the plurality of side members as shown in FIG. 1. In some such embodiments, the third distance may intersect one or more other stiffeners of the plurality of stiffeners. In other embodiments, the third distance may be between one side member of the plurality of side members and one other stiffener of the plurality of stiffeners. In still other embodiments, the third distance may be between two other stiffeners of the plurality of stiffeners.

The plurality of stiffeners may also comprise at least a fourth stiffener (164) as shown in FIG. 1. When present, the fourth stiffener will span a fourth distance. In some embodiments, the fourth distance may be between at least two side members of the plurality of side members as shown in FIG. 1. In some such embodiments, the fourth distance may intersect one or more other stiffeners of the plurality of stiffeners. In other embodiments, the fourth distance may be between one side member of the plurality of side members and one other stiffener of the plurality of stiffeners. In still other embodiments, the fourth distance may be between two other stiffeners of the plurality of stiffeners.

The plurality of stiffeners may further comprise at least a fifth stiffener (165) as shown in FIG. 1. When present, the fifth stiffener will span a fifth distance. In some embodiments, the fifth distance may be between at least two side members of the plurality of side members as shown in FIG. 1. In some such embodiments, the fifth distance may intersect one or more other stiffeners of the plurality of stiffeners. In other embodiments, the fifth distance may be between one side member of the plurality of side members and one other stiffener of the plurality of stiffeners. In still other embodiments, the fifth distance may be between two other stiffeners of the plurality of stiffeners.

The plurality of stiffeners may further comprise at least a sixth stiffener (166) as shown in FIG. 1. When present, the sixth stiffener will span a sixth distance. In some embodiments, the sixth distance may be between at least two side members of the plurality of side members as shown in FIG. 1. In some such embodiments, the sixth distance may intersect one or more other stiffeners of the plurality of stiffeners. In other embodiments, the sixth distance may be between one side member of the plurality of side members and one other stiffener of the plurality of stiffeners. In still other embodiments, the sixth distance may be between two other stiffeners of the plurality of stiffeners.

While the embodiment shown in FIG. 1 includes six stiffeners, embodiments may exist having more or less than six stiffeners. That is to say that the number of stiffeners may be any positive integer in a range selected from the group consisting of between 1 and 100, between 1 and 50, between 1 and 25, between 1 and 10, between 2 and 100, between 2 and 50, between 2 and 25, and between 2 and 10.

Also shown in FIG. 1 is an optional port (170). When present, a port may exist at an intersection point between at least two stiffeners of the plurality of stiffeners. The port—when present—will comprise at least one sidewall with a through hole passing through the side wall substantially perpendicular with or perpendicular with the panel plane. When present, the port provides a passage in the panel (100) through which additional structural or non-structural components such as vent tubes, HVAC conduits, plumbing, and electrical components may pass and/or may be attached. One example of a non-structural component which may be attached at a port is disclosed in International Patent Publication No. WO 2020/086518 A1, the teachings of which are incorporated by reference herein in their entirety. While the embodiment shown in FIG. 1 includes a single port, embodiments may exist comprising multiple ports with each port located at a different stiffener intersection point.

FIG. 1 shows the port (150) oriented perpendicular to the panel's horizontal plane (i.e.—the port's central axis having a 90° angle relative to the panel's horizontal plane). However, embodiments may exist—not shown—in which the port is not oriented perpendicular to the panel's horizontal plane. In some embodiments, the port may be oriented parallel to the panel's horizontal plane (i.e.—the port's central axis having a 0° angle relative to the panel's horizontal plane). In other embodiments, the central axis of the port may form an angle with the panel's horizontal plane with the angle being in the range of between 1° and 359°.

In some embodiments, each of the panels (100) may include one or more ports (150) oriented substantially parallel with the corresponding panel's horizontal plane. Once assembled in a roof deck (12 as shown in FIG. 5) as disclosed herein, one or more of the ports of one panel may be fluidly connected to one or more ports of a second panel forming a lattice work through which air may flow allowing for additional insulating and cooling effect.

While FIG. 1 shows the panel (100) comprised of a single unitary piece of material, embodiments may exist in which the panel is fabricated of two pieces of material—an upper section and a lower section—which are then snapped together to form the panel. Such embodiments allow for one or more of the panel side members and/or one or more of the stiffener's to be fabricated in two sections which snap together with the panel side member and/or stiffener having a hollow interior.

Preferably, the panel (100) will further comprise the insulating material (200) as shown in FIG. 2. When present, the insulating material may or may not fill the space created by the void (150 as shown in FIG. 1) including the one or more smaller voids created by the plurality of stiffeners.

Insulating material is commonly used in various aspects of building construction. Common examples of insulating materials include polymer insulation materials (such as polyurethane, polystyrene, polyisocyanurate, and the like), cellulosic insulating materials (including wood fiber), composite insulating materials (such as fiberglass), metallic insulating materials (such as aluminum sheet), perlite insulating materials and gaseous insulating materials (such as air or argon, often contained in a rigid or flexible envelope).

Another insulating material is commonly referred to as phase change material (PSM). In general, phase change materials are those materials which absorbs heat applied to the material during conversion of the material from a solid state to a liquid state (or a liquid to a gaseous state) with the phase change material maintaining a substantially constant temperature. The heat absorbed by the phase change material during the solid to liquid (or liquid to gas) conversion is released when the phase change material gives up its latent heat of liquification or gasification and turns back to a solid state. Examples of phase change materials include paraffin, calcium chloride hexahydrate, sodium sulfate, and Glauber's salt. Phase change materials are often used as an insulating material with the phase change material often forming an intermediate layer between two other layers of insulating material. Examples of phase change materials used as insulating materials are disclosed in U.S. Pat. Nos. 5,626,936 A, 5,770,295 A, and 6,645,598 B2, the teachings of each of which are incorporated by reference herein in their entirety.

The insulating material will have an R-Value which is a measure of how well the material resists the conductive flow of heat. An exemplary method for measuring R-Value of an insulating material is disclosed in ASTM C1289-22—Standard Specification for Faced Rigid Cellular Polyisocyanurate Thermal Insulation Board. Preferably the R-Value of the insulating material will be selected from the group consisting of at least R-5, at least R-15, at least R-25, at least R-35, at least R-40, at least R-45, at least R-50, and at least R-55.

FIG. 3 depicts a cross section of one embodiment of a panel (100). In the cross section shown in FIG. 3 the third side member (130), the first stiffener (161), the sixth stiffener (166), and the insulating material (200) are visible.

The individual side members and individual stiffeners may have a number of different cross-sectional profiles. For example, FIG. 3 shows the third side member (130) having an “L” shaped cross-sectional profile. FIG. 3 also shows the first stiffener (161) and the sixth stiffener (166) having a “T” shaped cross-sectional profile. In other embodiments, one or more of the side members and/or one or more of the stiffeners may have an “I” shaped cross-sectional profile. When a side-member and/or a stiffener has an “I” shaped cross-sectional profile, the “I” may be oriented perpendicular to the horizontal plane of panel (100) or parallel with the horizontal plane of the panel.

For clarification, each side member may individually have a cross-sectional profile selected from the group consisting of an “I” shaped cross-sectional profile, an “L” shaped cross-sectional profile, and a “T” shaped cross-sectional profile. Similarly, each stiffener may individually have a cross-sectional profile selected from the group consisting of an “I” shaped cross-sectional profile, an “L” shaped cross-sectional profile, and a “T” shaped cross-sectional profile.

FIG. 3 also shows the third side member (130) having a third side member height (135). One of ordinary skill will understand that each of the first side member (110 as shown in FIG. 1) will also have a first side member height. Preferably, the first side member height and the third side member height will be substantially equal to or equal to one another. Correspondingly, the second side member (120 as shown in FIG. 1) and fourth side member (140 as shown in FIG. 1) will each have a top edge and a bottom edge which are substantially parallel to one another resulting in a substantially flat or flat panel.

In some embodiments—not shown—the first side member height may be greater than or less than the third side member height (135 as shown in FIG. 3). The first side member height may be in a range selected from the group consisting of between 0.5 and 12 inches greater or less than the third side member height, between 0.5 and 10 inches greater or less than the third side member height, between 0.5 and 6 inches greater or less than the third side member height, and between 0.5 and 2 inches greater or less than the third side member height. Correspondingly, the second side member (120 as shown in FIG. 1) and the fourth side member (140 as shown in FIG. 1) may have a top edge which is not parallel with the bottom edge of said side member and forms an angle relative to bottom edge. This results in a panel having a sloped surface.

While the heights of the side members have been described and illustrated with respect to the third side member (130) as shown in FIG. 3, one of ordinary skill will recognize that the first side member (110 as shown in FIG. 1), the second side member (120 as shown in FIG. 1), and the fourth side member (140 as shown in FIG. 1) will also have corresponding side member heights. In some embodiments, the second side member height may be substantially equal to or equal to the fourth side member height. Correspondingly, the first side member and third side member will each have a top edge and a bottom edge which are substantially parallel to one another resulting in a substantially flat or flat panel.

In other embodiments—not shown—the second side member height may be greater than or less than the fourth side member height. The second side member height may be in a range selected from the group consisting of between 0.5 and 12 inches greater or less than the fourth side member height, between 0.5 and 10 inches greater or less than the fourth side member height, between 0.5 and 6 inches greater or less than the fourth side member height, and between 0.5 and 2 inches greater or less than the fourth side member height. Correspondingly, the first member side and the third side member may have a top edge which is not parallel with the bottom edge of said side member and forms an angle relative to bottom edge. This results in a panel having a sloped surface.

In the embodiment shown in FIG. 3, the panel (100) comprises the insulating material (200). In this embodiment the insulating material is in the form of a single layer of insulating material—referred to herein and in the claims as the first layer of insulation (210). The first layer of insulation may be of any type of insulating material described herein. Preferably, the first layer of insulation may be of a type of insulating material having an R-Value selected from the group consisting of at least R-5, at least R-15, at least R-25, at least R-35, at least R-40, at least R-45, at least R-50, and at least R-55.

FIG. 4 depicts a cross section of another embodiment of a panel (100). Like FIG. 3, the cross section shown in FIG. 4 shows the third side member (130), the first stiffener (161), the sixth stiffener (166), and the insulating material (200).

In the embodiment shown in FIG. 4, the panel (100) comprises the insulating material (200). In this embodiment the insulating material is in the form of three layers of insulating material—referred to herein as the first layer of insulation (210), the second layer of insulation (220), and the third layer of insulation (230). Preferably, each of the first layer of insulation, the second layer of insulation, and the third layer of insulation will independently be of a type of insulating material having an R-Value selected from the group consisting of at least R-20, at least R-25, at least R-30, at least R-35, at least R-40, at least R-45, at least R-50, and at least R-55.

Three layers of insulating material is considered particularly useful in embodiments in which one of the layers of insulating material—preferably the second layer of insulation (220)— comprises a phase change material (PSM) of a kind and type disclosed herein. In such embodiments, the second layer of insulation may be an intermediate layer which exists between the first layer of insulation (210) and the third layer of insulation (230) as shown in FIG. 4. In such embodiments, the first layer of insulation and third layer of insulation may each independently comprise a type of insulation selected from the group consisting of polymer insulation materials (such as polyurethane, polystyrene, polyisocyanurate, and the like), cellulosic insulating materials (including wood fibers), composite insulating materials (such as fiberglass), metallic insulating materials (such as aluminum sheet), and perlite insulating materials.

FIG. 5 depicts an embodiment of a plurality of panels (100) forming a roof deck (12) of a roof (10) of a building. In the embodiment shown in FIG. 5, six individual panels have been joined along their edges in a two by three configuration to form a monolithic roof deck. While FIG. 5 shows each panel oriented in substantially the same direction forming a 2 panel by 3 panel grid, embodiments may exist in which one or more of the panels is rotated on an axis perpendicular to the panel horizontal plane. Other embodiments may exist in which two or more panels may be attached to one another in a staggered pattern.

Joining the individual panels along their edges may be accomplished in a variety of manners. In some embodiments, opposing side members of opposing panels may include one or more attachment mechanisms integrally attached to said side member. One example of such an attachment mechanism is a tongue and groove attachment mechanism in which one or more tongues integrally attached to one side member of one panel engage with corresponding grooves integrally attached to a side member of a different panel to connect the two panels to one another. Another example of such an attachment mechanism is a hook and loop attachment mechanism in which one or more hooks integrally attached to one side member of one panel engage with corresponding loops integrally attached to a side member of a different panel to connect the two panels to one another. Alternatively, or in addition to the attachment mechanisms described above, the individual panels may be joined to one another by one or more fasteners, such as screw(s), bolt(s), clip(s), clamp(s), and the like which connect one side member of one panel to a side member of a different panel. Preferably the panels will be joined to one another in a substantially airtight and/or waterproof manner, which may be assisted by way of a gasket or sealant material applied between the side members of the opposing panels. Similarly, the panels may be affixed to the roof frame of the building by a plurality of connectors (17) such as screws, bolts, clips, or clamps which connect side member(s) of the panel(s) to the roof frame members. In some embodiments, the panels may be lashed to the roof frame members.

While FIG. 5 shows a single layer of panels (100) forming a roof deck (12), one of ordinary skill will recognize that the roof deck may be formed of multiple layers of panels. For example, some embodiments may include a roof deck formed of two or more layers of panels. The number of layers of panels in any one individual embodiment of a roof deck may be any integer greater than 0.

In certain embodiments, one or more—preferably all—of the panels (100) used to form the roof deck may include one or more surface features on a side of the panel facing the exterior of the building. Such surface features may include a non-slip surface such as a plurality of grooves or treads which increases the coefficient of friction between the panel surface and the footwear of an individual walking on the roof deck. Other surface features may include a colored coating which may inform those maintaining the building of the condition of the roof deck over time by allowing observation of areas in which the colored coating has faded or worn away allowing a different color of the panel side members, panel stiffeners, and/or insulating material to show through.

FIG. 6 depicts an embodiment of a plurality of panels (100) forming a roof deck (12) of a roof (10) of a building. In the embodiment shown in FIG. 5, a membrane (15) is applied over a portion of the roof deck. Preferably the membrane will be applied over the entirety of the roof deck. The membrane may be formed of any type of material commonly used in roofing membranes including rubbers (such as ethylene propylene diene monomer rubber), polymers (such as polyvinyl chloride, thermoplastic polyolefins, ketone ethylene ester), spray polyurethane foam, and liquid-applied membranes each of which are well known in the art. In certain embodiments, instead of or in addition to a membrane, the roof may include a ballasting material such as stone or gravel ballast.

While FIG. 6 shows the membrane (15) applied over the roof deck (12) after assembly of the panels to form the roof deck, other embodiments may exist. For example, in some embodiments, a membrane or other moisture barrier material may be applied to one or both of the top and/or bottom surfaces of one or more of the panels (100) prior to assembling the panels into a roof deck.

FIG. 7 depicts an embodiment of a plurality of panels (100) forming a portion of a wall (50) of a building. In the embodiment shown in FIG. 7, panels have been installed in the gaps between three studs (55) of the wall frame. These panels may be affixed to the studs of the wall of the building by a plurality of fasteners such as screws, bolts, clips, or clamps which connect side member(s) of the panel(s) to the studs. While FIG. 7 shows the panels installed in the gaps between studs, in some embodiments the panels may replace one or more of the studs themselves with the panel acting as a combination stud and insulation structure.

The various components of the panel—including the side members, the stiffeners, and the optional port(s)—may be fabricated of any number of materials using any number of manufacturing techniques which are well known in the art. Preferably, the components of the panel will be fabricated of a rigid material, nonlimiting examples of which include rigid plastics and metals (aluminum, steel, and the like). When the panel is fabricated of rigid plastics, non-limiting examples of manufacturing techniques for fabricating the panel include injection molding and hydroforming.

The insulating material may be added to the panel in a variety of ways. In some embodiments, the insulating material may be added to the panel during the panel manufacturing process such that the panel arrives at the job site “ready to install” with insulating material already included. In other embodiments, the insulating material may be field added to the panel at the job site either prior to or after installation of the panel on the roof or in the wall.

The panels described herein may be used as a combination roof deck and insulating material (and optionally a water barrier). As the panels may be constructed of light weight materials such as rigid plastic and may come in pre-fabricated sheets (such as a 4 by 4 square or a 4 by 8 rectangle) they may be easily lifted to the top of the building for installation requiring less effort than traditional roof decking in the form of metal sheets (i.e.—corrugated aluminum). The insulating material being pre-installed in the voids of the panel also reduces the cost and labor hours associated with installing the roof by eliminating the need to install insulation on top of the roof deck after the roof deck has been installed. Pre-installing the moisture barrier on the surface of the panel further reduces the cost and labor hours associated with applying a moisture barrier by eliminating the need to install a membrane on top of the insulating material after the roof deck has been installed. Finally, the monolithic structure with multiple panels connected by interlocking side members is considered more resistant to wind uplift damage than conventional roof deck materials and attachment methods. It is believed that—even in the event of extreme high wind speeds—at most a subset of individual panels may be damaged which can then easily be replaced or repaired as opposed to current roof deck systems which often require repair or replacement of the entire roof deck.

Claims

1. A panel (100) comprising:

a plurality of side members comprising at least a first side member (110), a second side member (120), and a third side member (130);

a void (150) between at least the first side member, the second side member, and the third side member; and

a plurality of stiffeners comprising at least a first stiffener (161) spanning a first distance between at least two side members of the plurality of side members; and

wherein the void is capable of receiving an insulating material (200).

2. The panel of claim 1, wherein the plurality of side members further comprises at least a fourth side member (140).

3. The panel of claim 1, wherein at least one of the side members of the plurality of side members has an “I” shaped cross-sectional profile.

4. The panel of claim 1, wherein at least one of the side members of the plurality of side members has an “L” shaped cross-sectional profile.

5. The panel of claim 1, wherein at least one of the side members of the plurality of side members has a “T” shaped cross-sectional profile.

6. The panel of claim 1, wherein the plurality of stiffeners further comprises at least a second stiffener (162) spanning a second distance between at least two side members of the plurality of side members or between one side member of the plurality of side members and the first stiffener.

7. The panel of claim 6, wherein the plurality of stiffeners further comprises at least a third stiffener (163) spanning a third distance between at least two side members of the plurality of side member, or between one side member of the plurality of side members and one other stiffener of the plurality of stiffeners, or between two other stiffeners of the plurality of stiffeners.

8. The panel of claim 1, wherein at least one of the stiffeners of the plurality of stiffeners has an “I” shaped cross-sectional profile.

9. The panel of claim 1, wherein at least one of the stiffeners of the plurality of stiffeners has an “L” shaped cross-sectional profile.

10. The panel of claim 1, wherein at least one of the stiffeners of the plurality of stiffeners has an “T” shaped cross-sectional profile.

11. The panel of claim 1, wherein an intersection point between at least two stiffeners of the plurality of stiffeners comprises a port (170).

12. The panel of claim 1, further comprising the insulating material.

13. The panel of claim 12, wherein the insulating material has an R-Value selected from the group consisting of at least R-5, at least R-15, at least R-25, at least R-35, at least R-40, at least R-45, at least R-50, and at least R-55.

14. The panel of claim 12, wherein the insulating material comprises a first layer of insulation (210).

15. The panel of claim 12, wherein the insulating material comprises at least a first layer of insulation (210), a second layer of insulation (220), and a third layer of insulation (230), and wherein the second layer of insulation is located between the first layer of insulation and the third layer of insulation.

16. The panel of claim 15, wherein the second layer of insulation comprises a phase change material.

17. The panel of claim 16, wherein the phase change material is selected from the group consisting of paraffin, calcium chloride hexahydrate, sodium sulfate, and Glauber's salt.

18. The panel of claim 1, wherein at least one side member of the plurality of side members comprises an attachment mechanism configured to connect the panel to an adjoining panel.

19. The panel of claim 1, wherein the panel is a roofing panel configured to be installed on a roof.

20. The panel of claim 1, wherein the panel is a wall panel configured to be installed in a wall.