Structural insulating panel and flat roof structure employing same

Abstract

A structural insulating panel for use in a flat roof structure comprises upper and lower structural layers and an intermediate layer between the upper and lower structural layers. The intermediate layer is shaped such that the upper structural layer is sloped relative to a generally horizontal plane when the structural insulating panel is installed in a flat roof structure.

1 . A structural insulating panel for use in a flat roof structure comprising:
 upper and lower structural layers; and an intermediate layer between said upper and lower structural layers, said intermediate layer being shaped such that said upper structural layer is sloped relative to a generally horizontal plane when said structural insulating panel is installed in a flat roof structure.   
     
     
         2 . A structural insulating panel according to  claim 1  wherein said intermediate layer is shaped such that the upper structural layer is sloped in multiple dimensions relative to said horizontal plane. 
     
     
         3 . A structural insulating panel according to  claim 2  wherein said intermediate layer is shaped such that the upper structural layer slopes generally linearly downwardly in two generally orthogonal directions. 
     
     
         4 . A structural insulating panel according to  claim 2  Wherein said intermediate layer is shaped such that the upper structural layer curves downwardly in different directions. 
     
     
         5 . A structural insulating panel according to  claim 4  wherein an upper surface of said intermediate layer on which said upper structural layer is disposed, has a generally parabolic shape. 
     
     
         6 . A structural insulating panel according to  claim 1  wherein said intermediate layer is shaped such that the upper structural layer slopes generally linearly downwardly in a single direction. 
     
     
         7 . A structural insulating panel according to  claim 1  wherein said intermediate layer is formed of foam material. 
     
     
         8 . A structural insulating panel according to  claim 1  wherein said intermediate layer is sandwiched directly between said upper and lower structural layers. 
     
     
         9 . A structural insulating panel according to  claim 9  wherein thicknesses of said upper and lower structural layers are selected to give said structural insulating panel a desired fire rating. 
     
     
         10 . A structural insulating panel according to  claim 9  wherein said intermediate layer is shaped such that the upper structural layer is sloped in multiple dimensions relative to said horizontal plane. 
     
     
         11 . A structural insulating panel according to  claim 10  wherein said intermediate layer is shaped such that the upper structural layer slopes generally linearly downwardly in two generally orthogonal directions. 
     
     
         12 . A structural insulating panel according to  claim 10  wherein said intermediate layer is shaped such that the upper structural layer curves downwardly in different directions. 
     
     
         13 . A structural insulating panel according to  claim 12  wherein an upper surface of said intermediate layer on which said upper structural layer is disposed, has a generally parabolic shape. 
     
     
         14 . A structural insulating panel according to  claim 9  wherein said intermediate layer is shaped such that the upper structural layer slopes generally linearly downwardly in a single direction. 
     
     
         15 . A structural insulating panel according to  claim 9  wherein said intermediate layer is formed of foam material. 
     
     
         16 . A structural insulating panel according to  claim 15  wherein said foam material is one of expanded polystyrene foam, urethane foam, polyurethane foam and isocyanurate foam. 
     
     
         17 . A structural insulating panel according to  claims 9  wherein said upper and lower structural layers are formed of material selected from plywood, OSB, metal sheet or other suitable material. 
     
     
         18 . A structural insulating panel according to  claim 1  wherein each of said upper and lower structural layers has a thickness in the range of from about ⅛″ to about 1½″ and wherein said intermediate layer had a minimum thickness of about 1″ and a maximum thickness of about 16″. 
     
     
         19 . A flat roof structure comprising:
 a plurality of abutting structural insulating panels, each structural insulating panel spanning at least a pair of adjacent rafters of said flat roof structure and defining an upper decking surface on which roofing is applied, said structural insulating panels being configured such that said upper decking surface is non-horizontal thereby to promote drainage.   
     
     
         20 . A flat roof structure according to  claim 19  wherein said structural insulating panels are arranged at least one of end-to-end and side-to-side. 
     
     
         21 . A flat roof structure according to  claim 20  wherein adjacent structural insulating panels carry mating formations. 
     
     
         22 . A flat roof structure according to  claim 21  wherein said mating formations are tongues and grooves. 
     
     
         23 . A flat roof structure according to  claim 20  further comprising sealant to seal seams between adjacent structural insulating panels. 
     
     
         24 . A flat roof structure according to  claim 20  wherein each structural insulating panel comprises:
 upper and lower structural layers; and   an intermediate layer between said upper and lower structural layers, said intermediate layer being shaped such that said upper structural layer is sloped relative to a horizontal plane.   
     
     
         25 . A structural insulating panel according to  claim 24  wherein said intermediate layer is shaped such that the upper structural layer is sloped in multiple dimensions. 
     
     
         26 . A structural insulating panel according to  claim 25  wherein said intermediate layer is shaped such that the upper structural layer slopes generally linearly downwardly in two generally orthogonal different directions. 
     
     
         27 . A structural insulating panel according to  claim 25  wherein said intermediate layer is shaped such that the upper structural layer curves downwardly in different directions. 
     
     
         28 . A structural insulating panel according to  claim 24  wherein said intermediate layer is shaped such that the upper structural layer slopes generally linearly downwardly in a single direction. 
     
     
         29 . A structural insulating panel comprising:
 an intermediate layer sandwiched between and adhered to first and second structural layers, said intermediate layer varying in thickness such that said first and second structural layers are non-parallel.   
     
     
         30 . A structural insulating panel according to  claim 29  wherein said intermediate layer is formed of foam material. 
     
     
         31 . A structural insulating panel according to  claim 30  wherein said foam material is one of expanded polystyrene foam, urethane foam, polyurethane foam and isocyanurate foam. 
     
     
         32 . A structural insulating panel according to  claims 29  wherein said upper and lower structural layers are formed of material selected from plywood, OSB, metal sheet or other suitable material. 
     
     
         33 . A structural insulating panel according to  claim 29  wherein each of said upper and lower structural layers has a thickness in the range of from about ⅛″ to about 1⅛″ and wherein said intermediate layer had a minimum thickness of about 1″ and a maximum thickness of about 16″.