Building panel with impermeable surface layer

Abstract

The present invention is directed to prefabricated construction panels, which allow for an improved roofing system and method for installation. In one embodiment, panels are provided with a weather resistant surface layer pre-bonded to the panel with tabs extending beyond the panel body suitable for overlapping adjacent panels in order to form a weather resistant roof. In a further embodiment, the panels are prefabricated from Oriented Strand Board (OSB) with tar coated paper bound to one side which extends beyond the edges of the panel body to form the tabs. These features and others allow for the quick and efficient assembly of a weather resistant roof that is cost effective and safer to construct.

What is claimed is:  
     
         1 . A prefabricated construction panel comprising: 
 a. a panel body having an upper surface and a first edge;    b. a weather resistant surface layer fixed to the upper surface of the panel body; and    c. a weather resistant first tab extending beyond the first edge of the panel body a predetermined amount.    
     
     
         2 . The construction panel of  claim 1 , wherein the first tab is formed by extending the surface layer beyond the first edge of the panel body.  
     
     
         3 . The construction panel of  claim 1 , wherein the panel body includes a second edge and a weather resistant second tab fixed to the surface layer and extending beyond the second edge of the panel body a predetermined amount.  
     
     
         4 . The construction panel of  claim 3 , wherein the first and second edges are substantially perpendicular.  
     
     
         5 . The construction panel of  claim 4 , wherein a portion of the first tab that extends beyond the first edge of the panel body is connected to a portion of the second tab that extends beyond the second edge of the panel body.  
     
     
         6 . The construction panel of  claim 3 , wherein the first tab is formed by extending the surface layer beyond the first edge of the panel body, and the second tab is formed by extending the surface layer beyond the second edge of the panel body.  
     
     
         7 . The construction panel of  claim 6 , wherein the panel body is generally rectangular and the first edge is perpendicular to the second edge.  
     
     
         8 . The construction panel of  claim 7 , wherein a portion of the first tab that extends beyond the first edge of the panel body is connected to a portion of the second tab that extends beyond the second edge of the panel body.  
     
     
         9 . The construction panel of  claim 7 , wherein the surface layer comprises paper with an upper surface treated with a weather resistant coating.  
     
     
         10 . The construction panel of  claim 9 , wherein the weather resistant coating is tar.  
     
     
         11 . The construction panel of  claim 10 , wherein the panel body is comprised of oriented strand board.  
     
     
         12 . The construction panel of  claim 11 , wherein the surface layer has a textured upper surface to provide increased traction for walking.  
     
     
         13 . A prefabricated construction panel comprising: 
 a. a panel body having an upper surface, a first edge and a second edge; and    b. a weather resistant surface layer fixed to the upper surface of the panel body, the surface layer having a first tab portion extending beyond the first edge of the panel body a predetermined amount and a second tab portion extending beyond the second edge of the panel body a predetermined amount.    
     
     
         14 . The construction panel of  claim 13 , wherein the first edge and a second edge are substantially perpendicular to one another.  
     
     
         15 . The construction panel of  claim 14 , wherein the predetermined amount that the first tab portion extends beyond the first edge is sufficient to form an overlapping seam with an adjacent construction panel.  
     
     
         16 . The construction panel of  claim 15 , wherein the predetermined amount that the second tab portion extends beyond the second edge is sufficient to form an overlapping seam with an adjacent construction panel.  
     
     
         17 . A prefabricated roofing panel comprising: 
 a. a panel body having an upper surface and a first edge; and    b. a weather resistant surface layer fixed to the upper surface of the panel body, the surface layer having at least one tab extending beyond the first edge of the panel body a predetermined amount.    
     
     
         18 . The panel of  claim 17 , wherein the surface layer and tab are of unitary construction.  
     
     
         19 . A paneling system for use in construction of a roof, the paneling system comprising: 
 a. a plurality of rows of panels, each panel comprising: 
 a panel body, the panel body being generally rectangular with an upper surface and a first edge;  
 a weather resistant surface layer fixed to the upper surface of the panel body; and  
 a weather resistant first tab extending beyond the first edge of the panel body a predetermined amount;  
   b. wherein at least a portion of the panels in each row are positioned so that the first edge of each panel abuts one edge of an adjacent panel; and    c. wherein the first tab of each panel overlaps the abutting edge of the adjacent panel and is affixed thereto, whereby a weather resistant roofing surface is formed.    
     
     
         20 . The paneling system of  claim 19 , wherein: 
 a. each panel body has a second edge substantially perpendicular to the first edge and a weather resistant second tab extending beyond the second edge of the panel body a predetermined amount;    b. the panels in at least a portion of the rows are positioned so that the second edge of each panel abuts an edge of at least one adjacent panel in an adjacent row; and    c. the second tab of each panel overlaps the adjacent panel in the adjacent row, and the second tab is affixed to the weather resistant surface layer of the adjacent panel in the adjacent row, whereby a weather resistant roofing surface is formed.    
     
     
         21 . The paneling system of  claim 20 , wherein the first tab is formed by extending the surface layer beyond the first edge of the panel body, and the second tab is formed by extending the surface layer beyond the second edge of the panel body.  
     
     
         22 . The construction panel of  claim 21 , wherein a portion of the first tab that extends beyond the first edge of the panel body is connected to a portion of the second tab that extends beyond the second edge of the panel body.  
     
     
         23 . The paneling system of  claim 21 , wherein the surface layer comprises paper with an upper surface treated with a weather resistant coating.  
     
     
         24 . The paneling system of  claim 23 , wherein the weather resistant coating is tar.  
     
     
         25 . The paneling system of  claim 24 , wherein the panel body is comprised of oriented strand board.  
     
     
         26 . The paneling system of  claim 25 , wherein the first and second tabs are affixed to adjacent panels by an adhesive.  
     
     
         27 . The paneling system of  claim 20 , wherein the panels in at least a portion of the rows are positioned so that the second edge of each panel in the row abuts an edge of two adjacent panels in the adjacent row, the second tab of each panel overlaps the adjacent edge of the two adjacent panels in the adjacent row, and the second tab is affixed to the weather resistant surface layer of the two adjacent panels.  
     
     
         28 . A method for installing a paneling system for use in constructing a roof, the method comprising the steps of: 
 a. providing a plurality of rows of panels, each panel comprising: 
 a panel body, the panel body being generally rectangular with an upper surface, a first edge, and a second edge;  
 a weather resistant surface layer fixed to the upper surface of the panel body;  
 a weather resistant first tab extending beyond the first edge of the panel body a predetermined amount; and  
 a weather resistant second tab extending beyond the second edge of the panel body a predetermined amount;  
   b. positioning at least a portion of the panels in each row so that the first edge of each panel abuts one edge of an adjacent panel;    c. overlapping the first tab of each panel over the abutting edge of the adjacent panel;    d. positioning the panels in at least a portion of the rows so that the second edge of each panel in the row abuts an edge of at least one adjacent panel in an adjacent row;    e. overlapping the second tab of each panel over an abutting edge of at least one adjacent panel in an adjacent row; and    f. affixing the first tab of each panel in each row to the adjacent panel in the row and affixing the second tab of each panel to the adjacent panel in the adjacent row, whereby a weather resistant roofing surface is formed.    
     
     
         29 . The method of  claim 28 , wherein the first tab is formed by extending the surface layer beyond the first edge of the panel body, and the second tab is formed by extending the surface layer beyond the second edge of the panel body.  
     
     
         30 . The method of  claim 29 , wherein a portion of the first tab that extends beyond the first edge of the panel body is connected to a portion of the second tab that extends beyond the second edge of the panel body.  
     
     
         31 . The method of  claim 29 , wherein the surface layer comprises paper with an upper surface treated with a weather resistant coating.  
     
     
         32 . The method of  claim 31 , wherein the weather resistant coating is tar.  
     
     
         33 . The method of  claim 32 , wherein the panel body is comprised of oriented strand board.  
     
     
         34 . The method of  claim 33 , wherein the first and second tabs are affixed to adjacent panels by an adhesive.  
     
     
         35 . The method of  claim 28 , wherein the panels in at least a portion of the rows are positioned so that the second edge of each panel in the row abuts an edge of two adjacent panels in the adjacent row, the second tab of each panel overlaps the adjacent edge of the two adjacent panels in the adjacent row, and the second tab is affixed to the weather resistant surface layer of the two adjacent panels.