Structural insulated roof panels with rigid foam core
View Patent ↗A structural insulated roof panel with a rigid foam core is disclosed. A particular embodiment includes a rigid foam core having first and second faces, a plurality of support channels being formed on the first and second faces of the rigid foam core, each of the support channels being formed in the rigid foam core with at least one bend; and a plurality of supports being insertable into the plurality of support channels such that at least one face of each of the plurality of supports is external to the first and second faces of the rigid foam core and substantially flush with a face of the rigid foam core, each of the plurality of supports being fabricated using at least four bends to produce a support that fits within one of the plurality of support channels.
1. A method of fabricating a structural insulated roof panel, the method comprising:
forming a plurality of support channels on first and second faces of a rigid foam core, each of the support channels being formed in the rigid foam core as voids cut into the rigid foam core thereby enabling slideable insertion of a support into the void of each support channel, first support channels on the first face of the rigid foam core being formed as voids with two bends and configured to fit corresponding supports having four bends, second support channels on the second face of the rigid foam core being formed as voids with four bends and configured to fit corresponding supports having six bends;
inserting a plurality of first supports into the voids provided by the first support channels such that one face of each of the plurality of first supports being external to the first face of the rigid foam core and substantially flush with the first face of the rigid foam core, each of the plurality of first supports being fabricated as a structure having four bends and including a portion corresponding to a shape of the first support channels, wherein each of the plurality of first supports has a hat channel shape in cross-section; and
inserting a plurality of second supports into the voids provided by the second support channels such that one face of each of the plurality of second supports being external to the second face of the rigid foam core and substantially flush with the second face of the rigid foam core, each of the plurality of second supports being fabricated as a structure having six bends and including a portion corresponding to a shape of the second support channels.
2. The method as claimed in claim 1 including joining a structural insulated roof panel with a structural insulated wall panel in a substantially perpendicular arrangement using a strap.
3. The method as claimed in claim 1 including joining two structural insulated roof panels with rigid foam cores at a building truss.
4. The method as claimed in claim 1 including joining a cantilevered structural insulated roof panel with a rigid foam core with a structural insulated wall panel with a rigid foam core as configured for a load-bearing condition.
5. The method as claimed in claim 1 including joining a structural insulated roof panel with a rigid foam core with a structural insulated wall panel with a rigid foam core as configured for a load-bearing condition.
6. The method as claimed in claim 1 including joining a structural insulated roof panel with a rigid foam core with a structural insulated wall panel with a rigid foam core as configured for a non-load-bearing condition.
7. The method as claimed in claim 1 including joining a cantilevered structural insulated roof panel with a rigid foam core with a structural insulated wall panel with a rigid foam core as configured for a non-load-bearing condition.
8. The method as claimed in claim 1 including joining a structural insulated roof panel with a rigid foam core with a structural insulated wall panel with a rigid foam core.