U.S. patent application number 10/436758 was filed with the patent office on 2004-11-18 for building panel with impermeable surface layer.
Invention is credited to Byrd, Bobby Joe.
Application Number | 20040226247 10/436758 |
Document ID | / |
Family ID | 33417238 |
Filed Date | 2004-11-18 |
United States Patent
Application |
20040226247 |
Kind Code |
A1 |
Byrd, Bobby Joe |
November 18, 2004 |
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.
Inventors: |
Byrd, Bobby Joe; (Woodworth,
LA) |
Correspondence
Address: |
Floyd R. Nation
750 Bering Drive
Houston
TX
77057-2198
US
|
Family ID: |
33417238 |
Appl. No.: |
10/436758 |
Filed: |
May 13, 2003 |
Current U.S.
Class: |
52/518 |
Current CPC
Class: |
E04D 3/358 20130101;
E04D 3/35 20130101; E04D 3/351 20130101 |
Class at
Publication: |
052/518 |
International
Class: |
E04D 001/00 |
Claims
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.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to improvements in
building panels typically used for roof construction and
weatherproofing. More particularly, the present invention provides
an improved roofing panel that allows for an improved roofing
system and method for construction. Each panel is prefabricated
with an impermeable surface layer bonded to the panel with one or
more overlapping edges. Thus, the impermeable surface layer of each
panel extends onto the surface layer of an adjacent panel to
provide a weather resistant roof that eliminates the construction
step of separately installing a water resistant layer such as tar
paper or other impermeable materials while on the rooftop.
BACKGROUND OF THE INVENTION
[0002] Weather resistant roofing is a crucial requirement for any
successful building, and a number of methods have been used. In
conventional home construction, roofs are often constructed by
laying a weather resistant felt liner on a roofing deck, then
applying shingles and long strips of liner that overlap the
shingles. This process is expensive and time consuming, and may
create a safety risk based on the additional time workers must
spend on the roof. Additionally, nail holes can allow leaks over
time, and wind uplift forces can readily damage the shingles.
[0003] Other roofing systems use panels to provide for quicker
installation. Metal panels which overlap or interlock are often
used, however heat induced expansion and contraction of the metal
can lead to cracks or gaps through which moisture may enter the
building. Metal roofing panels are also difficult to shape for
fitting corners and angles.
[0004] Another type of roofing system is the single-ply membrane
roof, in which an insulation barrier like foam or wood is installed
in panels on the roofing deck, and then impermeable sheets of a
polymeric material such as ethylene propylene diene rubber (EPDM)
are installed over the insulation panels. Single-ply roofs allow
for faster construction than shingled roofs, however there are
difficulties in attaching the membrane to the insulation panels.
Mechanically fastening large sheets of membrane to the roofing deck
requires careful labor and creates problems of wind uplift and
water leakage. Likewise, using adhesives over the entire surface
requires additional time and expense. Additionally, an area around
the edges of the membrane sheets must often be cleaned in order to
create a good seal when adjacent sheets are attached to one
another. Plus, all construction must take place on the rooftop
itself, creating difficult working conditions and a safety
hazard.
[0005] As such, because of the necessity of having a weather
resistant roof and because of the time and expense involved in
building one, there is a need for an improved roofing material and
method for installation that is efficient, quick, and reliable.
Also, because construction often takes place on the rooftop, there
is a need for a roofing system and construction method that reduce
the time workers spend on the roof and thus improve safety.
SUMMARY OF THE INVENTION
[0006] The present invention is therefore directed to a weather
resistant roofing panel, a roofing system using this panel, and a
method for construction.
[0007] One aspect of the present invention relates to providing a
prefabricated roofing panel that is cost effective to produce and
install. Another aspect relates to an improved roofing system that
may be constructed more efficiently with less overall cost and
greater reliability while providing protection from the weather in
a shorter installation time.
[0008] Another aspect of this invention is to provide a roofing
panel that has an impermeable surface layer bonded to each panel
prior to its use in construction of a roof. An additional aspect is
to eliminate the need to attach weather resistant sheets at the
construction site while on the rooftop. A further aspect of this
invention is to provide a panel with an impermeable surface layer
that may be easily joined to adjacent panels and sealed. Yet
another aspect is to provide a roofing panel that may be joined to
adjacent panels and sealed without the need for additional roofing
components. Still another aspect is to provide a roofing panel in
which nails are not needed to attach the impermeable surface layer.
Additionally, the panel may include an impermeable surface layer
having a textured or prepared surface that provides greater
traction for the worker as he walks on the surface during
construction. A further aspect is to provide an impermeable surface
layer that reduces wrinkles. An additional aspect is to provide a
surface layer made from coated paper to facilitate installation,
weatherproofing, repairing, and bonding and to reduce expense.
[0009] Another aspect of this invention is to provide a versatile
roofing panel that may be easily cut or altered to fit any roof
shape desired. Further aspects stem from providing a roofing panel
made from Oriented Strand Board (OSB). OSB functions as insulation,
provides structural stability, reduces expenses, and may be easily
cut to fit different roof shapes. Yet another aspect of the present
invention is to provide a roofing panel that is resistant to wind
uplift and that is easy to repair.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a perspective view of a roofing panel according to
one embodiment of the present invention.
[0011] FIG. 2 is a cross-sectional view of the panel of FIG. 1
illustrating the layers of the invention.
[0012] FIG. 3 is a perspective view of a roofing panel according to
another embodiment of the present invention.
[0013] FIG. 4 is an illustration of how the panels of FIG. 1 may be
installed.
[0014] FIG. 5 is an illustration of a roofing surface according to
one embodiment of the present invention.
[0015] FIG. 6 is an illustration of a roofing surface according to
another embodiment of the present invention.
DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0016] In order to provide a cost efficient roofing system that can
be quickly, efficiently, and safely installed, the present
invention relates to an improved roofing panel. This invention also
provides a roofing system and a method for construction based on
the new panel.
[0017] FIG. 1 illustrates one embodiment of the roofing panel
according to this invention. FIG. 2 provides a cross-sectional view
of the roofing panel in FIG. 1. In FIG. 1, a roofing panel 1 is
provided that includes a panel body 2 and a weather resistant
surface layer 3 having a first weather resistant tab 4 and a second
weather resistant tab 5. The weather resistant surface layer 3 is
bonded to the panel body 2. The first tab 4 extends beyond a first
edge 6 of the panel body 2, and the second tab 5 extends beyond a
second edge 7 of the panel body 2. When panels are installed as
illustrated in FIG. 4, the first and second tabs 4, 5 overlap the
surface layers 3 of adjacent panels and thus may be bonded or
fastened to create a seal over the line of abutment of the adjacent
panels. Thus, the portions of the first and second tabs 4, 5 that
extend beyond the edges of the panel body are preferably connected,
as shown in FIGS. 1 and 4, so as to create a continuous weather
resistant surface without gaps at the panel corners.
[0018] Additionally, in a further embodiment, the roofing panels
may be made so that the weather resistant surface layer 3 is not
bonded to the panel body 2 in a region along the edges of the panel
so that clips may be installed to hold adjacent panels. In this
manner, the consistency of the weather resistant surface layer 3 is
not compromised, and the weather resistant surface layer 3 may
overlap the clips. Furthermore, with this embodiment, the weather
resistant surface layer 3 may be lifted up along the edges of the
panel body 2 to allow for nails to be driven through roofing panel
without penetrating the weather resistant surface layer 3.
[0019] It should be understood that the presently preferred use of
the invention is for construction of roofs, but the panels may also
be used for other construction purposes such as exterior wall
sheathing, flooring, decking and other uses when an extended
weather resistant surface is desired.
[0020] In accordance with the present invention, the roofing panel
1 illustrated by FIG. 1 eliminates the need to separately install a
weather resistant surface layer 2 to roofing panels 1 after the
panels have been installed. Instead, the roofing panels 1 of the
present invention are prefabricated with a weather resistant
surface layer 2 attached. The first and second tabs 4, 5 provide a
waterproof layer across adjacent panel units by the use of an
overlapping relationship. These features eliminate construction
steps and components, thus saving time and expense and improving
safety.
[0021] One of skill in the art will also recognize that the panel
body 2 can be made of any desired material and can be selected to
function as insulation as well as simply support for the roof. For
example, composite wood such as Oriented Strand Board (OSB) or
plywood may be used for the panel body to provide insulation,
structural support, and stability. For example, a panel of the
present invention made from OSB would typically have a thickness
suitable for the particular purpose such as 1/4 inch to 1 inch and
may be 4 feet by 8 feet or 4 feet by 12 feet in size. The tabs 4, 5
may extend beyond the edge of the panel body 2 an appropriate
amount such as 1/2 inch to 2 inches typically. Furthermore the
weight of the OSB panel body 2 increases the panel's resistance to
wind uplift when the surface layer 3 is bonded tightly to the
panel. An OSB panel body 2 also allows for greater versatility in
roof construction as the panel body 2 may easily be cut to fit the
dimensions of the roof. Additionally, OSB also helps to reduce
cost. One of skill in the art will recognize that other types of
materials may also be used depending upon the particular
application. One of skill in the art will also recognize that
conventional plywood, foam, polymers, or other materials may also
be used for the panel body 2.
[0022] One embodiment of the present invention may use coated paper
as the weather resistant surface layer 3. The paper may be coated
on one surface with any water resistant material such as tar, felt,
polyethylene, or plastic. The uncoated surface of the paper may be
readily bonded with an acceptable adhesive to the surface of the
OSB panel body 2. The coating also makes the paper substantially
impermeable to water and can provide traction for walking on the
roof. The first and second tabs 4, 5 may then be formed by simply
extending the length of the paper over the first and second edges
6, 7, respectively, of the panel body 2 during fabrication of the
panels. Thus, the first and second tabs 4, 5 may be prefabricated
onto the panel without using additional sealing components. Using
coated paper also provides first and second tabs 4, 5 that are
flexible, easy to work with, and easy to cut or trim while being
resistant to tearing or destruction. Furthermore, coated paper may
reduce the cost of the roofing panel. However, one of skill in the
art will recognize that the weather resistant surface layer and
weather resistant tabs of this invention may be made using numerous
weather resistant materials, including polymeric membranes and
paper coated with other appropriate materials or particles.
Alternatively, panels may be prefabricated with separate tabs
pre-bonded to the surface layer 3. Thus, tabs could be made from
different material if desired.
[0023] The panel in FIG. 1 may be assembled into a paneling system
for use in roofing as is shown in the embodiment of this invention
represented by FIGS. 4 and 5. FIG. 4 shows a paneling system in
which panels are positioned adjacent to one another with their
edges abutting. FIG. 5 shows this paneling system assembled on a
roof. The paneling system of FIG. 4 may be constructed by
installing a series of adjacent rows. Initially, row 12 is
constructed by the steps of first positioning panel 8, then
positioning a second panel 9 so that edge 14 of panel 8 abuts
against edge 6 of panel 9. The first tab 4 of panel 9 may then
overlap a portion of panel 8. The second tab of panel 9 has been
removed because panel 9 is on an end row. Likewise, the first and
second tabs of panel 8 have been removed because it is an end
panel. Alternatively, tabs on end panels can be folded onto the
panel body 2 or attached to adjacent structures if desired. End
panels may also be cut or trimmed to fit the dimensions of any
roof. Additional panels (not shown) may also be added to row 12 as
desired according to the above method.
[0024] Next, row 13 of FIG. 4 is constructed by positioning panel
10 adjacent panel 8 so that edge 7 of panel 10 abuts edge 15 of
panel 8 and second tab 5 of panel 10 overlaps a portion of panel 8.
Then panel 11 is positioned adjacent to and abutting panel 10 and
panel 9 so that the first and second tabs 4, 5 of panel 11 overlap
a portion of the adjacent panels. Additional panels and rows of
panels (not shown) may be added to the paneling assembly in
accordance with the above steps. The first and second tabs 4, 5 of
each panel may then overlap a portion of the adjacent panels and,
if desired, be attached to the surface layers 3 of the adjacent
panels. One of skill in the art will also recognize that the panels
can be installed in a different sequence as long as the tabs
overlap adjacent panels. Furthermore, although the panels of this
invention may be effectively oriented in many positions, if a roof
is sloped, then overlapping the second tab in a downwards direction
will facilitate the flow of water over the panels. Additionally, if
the weather resistant surface layer 3 of each panel is not bonded
to the panel body 2 along its edges, then clips can be installed
against the panel body 2, underneath the weather resistant surface
layer 3 and underneath the overlapping tabs 4, 5, to hold adjacent
panels together.
[0025] Alternatively, rows of panels may be arranged in a staggered
arrangement for structural support, as is pictured in FIG. 6, with
each panel abutting two adjacent panels at that panel's second edge
7 and abutting another two adjacent panels at the opposite edge 15,
extending to the top and bottom of the roof. Thus, the second tab 5
of each panel would partially overlap two adjacent panels instead
of one.
[0026] One of skill in the art will recognize that roofing panels
are preferably assembled onto a roofing deck and may be attached to
the roofing deck using any number of methods known in the art. If
nails are used on the roofing panels, they may be positioned on the
edges so that the tabs may overlap the nail heads. Alternatively,
if the weather resistant surface layer 3 of each panel is not
bonded to the panel body 2 along its edges, then the weather
resistant surface layer 3 may be lifted up so that nails may be
driven through the panel body without penetrating the weather
resistant surface layer 3.
[0027] Additionally, the first and second tabs 4, 5 are preferably
bonded to the surface layers 3 on adjacent panels using an
appropriate adhesive running down the entire length of each tab so
that consecutive surface layers 3 are effectively sealed. Such an
adhesive may be applied by hand after the panels are attached in
position or the undersurface of the tabs may be provided with an
appropriate adhesive during manufacture. In this way, nails may be
unnecessary to connect the surface layers 3, and leakage through
nail holes can be reduced or avoided. However, mechanical fastening
means such as-staples may be used if desired to attach and retain
tabs 4, 5 in overlapping positions. Alternatively, other attaching
means known in the art may also be used to attach the tabs to
adjacent surface layers. Panels may also be prefabricated with
surface layers having no coating along one or more of their edges
for bonding purposes or with surface layers having a different
material or consistency along one or more of the edges.
Furthermore, the tabs could provide a sealing redundancy by the
steps of first attaching the tabs to adjacent panels, and then
overlaying the tabs with an additional sealing material such as an
appropriate tape. The roofing panel of this invention may also
comprise any number of tabs, connected or unconnected, including
only a single tab as is illustrated in FIG. 3. Additional sealing
may be used, if desired, by methods known in the art.
* * * * *