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US 10,590,653 B1Granted
Roof assemblies with inset solar panels, methods for their manufacture, and the use of such assemblies in a building
AssigneeCovestro LLC
InventorsJames L. Lambach, David M. Baily
Life of this patent
Estimating the term…
Abstract
Prefabricated insulated roof assemblies, methods for manufacturing such assemblies, and use of these roof assemblies in a building are described. The assemblies include a sheathing panel comprising an inset solar panel, I-joists, and a rigid foam insulation board positioned in a cavity formed by the sheathing panel and the I-joists.
Claims35
An insulated roof assembly comprising:
- (a) a sheathing panel comprising a solar panel inset therein, the sheathing panel comprising:
- (1) an upper surface, and
- (2) a lower surface;
- (b) a plurality of I-joists positioned in a spaced-apart and generally parallel relationship to each other, the I-joists comprising:
- (1) an upper flange,
- (2) a lower flange, and
- (3) a web extending between the upper flange and the lower flange, wherein the lower surface of the sheathing panel abuts an upper surface of the upper flange of the I-joists so that the sheathing panel, the solar panel, and the I-joists define a cavity;
- (c) a generally planar first rigid foam insulation board comprising:
- (1) an upper surface,
- (2) a lower surface,
- (3) a first side, and
- (4) a second side that is opposite of the first side,
- wherein the first rigid foam insulation board is positioned in the cavity such that:
- (1) the upper surface of the first rigid foam insulation board faces the lower surface of the upper flange of a first I-joist at the first side of the first rigid foam insulation board,
- (2) the upper surface of the first rigid foam insulation board faces the lower surface of the upper flange of a second I-joist at the second side of the first rigid foam insulation board,
- (3) an outer edge of the first side of the first rigid foam insulation board faces the web of the first I-joist, and
- (4) an outer edge of the second side of the first rigid foam insulation board faces the web of the second I-joist,
- wherein the insulated roof assembly comprises a ventilation channel having a thickness corresponding to the thickness of the upper flange of the first I-joist and the second I-joist.
15 more elements
A method for making a roof assembly comprising:
- (a) positioning an assembly on a support, the assembly comprising:
- (1) a first I-joist comprising an upper flange, a lower flange, and a web extending between the upper flange and the lower flange,
- (2) a second I-joist comprising an upper flange, a lower flange, and a web extending between the upper flange and the lower flange, and
- (3) a generally planar first rigid foam insulation board comprising an upper surface, a lower surface, a first side, and a second side that is opposite of the first side, and
- wherein:
- (i) the first I-joist and the second I-joist are positioned in a spaced-apart and generally parallel relationship to each other;
- and
- (ii) the first rigid foam insulation board is positioned between the first I-joist and the second I-joists such that:
- (A) the upper surface of the first rigid foam insulation board faces the lower surface of the upper flange of a first I-joist at the first side of the first rigid foam insulation board, (B) the upper surface of the first rigid foam insulation board faces the lower surface of the upper flange of a second I-joist at the second side of the first rigid foam insulation board, (C) an outer edge of the first side of the first rigid foam insulation board faces the web of the first I-joist, and (D) an outer edge of the second side of the first rigid foam insulation board faces the web of the second I-joist;
- and
- (b) squaring the assembly that is placed on the support;
- and
- (c) attaching a sheathing panel comprising an inset solar panel to the upper surface of the upper flange of the first and second I-joists of the squared assembly that is placed on the support,
- wherein the first rigid foam insulation board is positioned between the first I-joist and the second I-joist such that a ventilation channel having a thickness corresponding to the thickness of the upper flange of the first I-joist and the second I-joist is formed.
11 more elements
Dependencies are inferred from the claim text.