U.S. patent application number 11/881073 was filed with the patent office on 2008-01-17 for insulated pitched roofing system and method of installing same.
Invention is credited to David H. Faulkner, Robert L. Ferrante, E. Richard Huber, Pat L. Murray.
Application Number | 20080010933 11/881073 |
Document ID | / |
Family ID | 26968840 |
Filed Date | 2008-01-17 |
United States Patent
Application |
20080010933 |
Kind Code |
A1 |
Faulkner; David H. ; et
al. |
January 17, 2008 |
Insulated pitched roofing system and method of installing same
Abstract
An insulated pitched roofing system for a sloped deck in which
an insulating sheet is adhered to the sloped deck or to a roofing
substrate and the roof components are adhered to the insulating
sheet with a polymer adhesive. The polymer adhesive is preferably a
froth liquid polyurethane foam.
Inventors: |
Faulkner; David H.;
(Bradenton, FL) ; Ferrante; Robert L.; (Davie,
FL) ; Huber; E. Richard; (Houston, TX) ;
Murray; Pat L.; (Spring, TX) |
Correspondence
Address: |
ANDREWS & KURTH, L.L.P.
600 TRAVIS, SUITE 4200
HOUSTON
TX
77002
US
|
Family ID: |
26968840 |
Appl. No.: |
11/881073 |
Filed: |
July 25, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10294959 |
Nov 14, 2002 |
7249443 |
|
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11881073 |
Jul 25, 2007 |
|
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|
60334787 |
Nov 15, 2001 |
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Current U.S.
Class: |
52/411 ;
156/71 |
Current CPC
Class: |
B32B 21/10 20130101;
E04D 1/34 20130101; E04D 2001/3435 20130101; B32B 27/40 20130101;
B32B 5/18 20130101; B32B 7/10 20130101; B32B 11/04 20130101; E04D
11/02 20130101 |
Class at
Publication: |
052/411 ;
156/071 |
International
Class: |
E04B 7/02 20060101
E04B007/02 |
Claims
1. A method of installing an insulated pitched roofing system
having a plurality of roof components and a pitched roof deck, the
method comprising the steps of: adhering, with a polymer adhesive,
an insulating sheet to the pitched roof deck or to a roof substrate
attached to the pitched roof deck; and adhering the roof components
to the insulating sheet.
2. The method of claim 1, wherein said roof component adhering step
comprises: applying a polymer adhesive on the insulating sheet;
placing a portion of a lower surface of a roof component in
substantial contact with the polymer adhesive; and allowing the
polymer adhesive to bond the roof component to the insulating
sheet.
3. The method of claim 2, wherein the polymer adhesive is a
polyurethane foam.
4. The method of claim 2, wherein the polymer adhesive is a two
component froth liquid polyurethane foam having a density of about
one to about four pounds per cubic foot and a reactivity period of
about one half to about ten minutes.
5. An insulated pitched roofing system for insulating a pitched
roof deck and attaching overlapping roof components thereto, the
system comprising: a plurality of insulation boards of unitary
construction, each said insulation board adhered and bonded to the
pitched roof deck, each said insulation board having a planer upper
surface and each said insulation board placed in abutting contact
with an adjacent said insulation board to form a continuous,
uniform insulative layer; a polymer adhesive adhering said
plurality of insulation boards to the pitched roof deck and said
polymer adhesive adhering the overlapping roof components to said
plurality of insulation boards.
6. The insulated pitched roofing system of claim 5, wherein said
polymer adhesive is a polyurethane.
7. The insulated pitched roofing system of claim 5, wherein said
polymer adhesive is a foamable polymer adhesive.
8. The insulated pitched roofing system of claim 7, wherein said
polymer adhesive is a plural component, liquid polyurethane
foam.
9. The insulated pitched roofing system of claim 5, wherein each
said board of said plurality of insulation boards includes a
substantially flat lower surface adhered to the pitched roof
deck.
10. The insulated pitched roofing system of claim 5, wherein each
said board of said plurality of insulation boards includes a
continuous flat upper surface to which the roof components are
adhered.
11. In a pitched roofing system having a deck, a waterproof
membrane attached to the deck, and overlapping profiled roof
components, the improvement comprising: an insulative layer between
the waterproof membrane and the profiled roof components, said
insulative layer comprising a plurality of insulation boards
arranged in contacting relationship with each other on the
waterproof membrane, each said insulation board having a generally
flat upper surface and a lower surface; a polymer adhesive adhering
said lower surface of said plurality of insulation boards to the
waterproof membrane; and said polymer adhesive adhering the
profiled roof components to said upper surface of said plurality of
insulation boards.
12. The pitched roofing system of claim 11, wherein said plurality
of insulation boards are made of expanded rigid polystyrene
plastic.
13. The pitched roofing system of claim 11, wherein said insulative
layer has a continuous planer upper surface.
14. The pitched roofing system of claim 13, wherein said polymer
adhesive is an expanding polyurethane foam.
15. An energy efficient, waterproof, pitched roofing system for
installation on a roof deck attached to a plurality of pitched
truss rafters, the system comprising: a waterproof substrate
attached to the roof deck; a plurality of insulation boards
arranged in contacting relationship with one another and adhesively
bonded to said waterproof substrate with a polymer adhesive, said
polymer adhesive being an expanding foam adhesive; and a plurality
of profiled roof components adhesively bonded to said plurality of
insulation boards with said polymer adhesive.
16. The pitched roofing system of claim 15, wherein said arranged
plurality of insulation boards comprise a substantially continuous
planer lower surface bonded to said waterproof substrate and a
substantially continuous planer upper surface.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of co-pending
U.S. patent application Ser. No. 10/294,959, filed Nov. 14, 2002,
which claims priority from Provisional Application Ser. No.
60/334,787, filed on Nov. 15, 2001. Applicant incorporates by
reference herein U.S. patent application Ser. No. 10/294,959.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a pitched roofing system,
and particularly to a system for insulating the pitched roof and
attaching roofing components, and a method for installing the
system.
[0004] 2. Description of the Related Art
[0005] There are two basic types of roofs: flat and pitched.
Pitched roofs come in a few basic styles, all of which are relevant
to the present invention. A duo-pitched roof has two sloping sides
joined along the top with end vertical walls called a gable end.
This is probably the most common form of pitched roof. If the end
of the roof is also sloping it is termed hipped. If two sections of
roof meet at an angle, such as a right angle, the junction between
the two roof sections is termed a valley.
[0006] Various roof components are used as roof coverings on
pitched roof decks. One example of a roof component is a roof tile.
Roof tiles are extremely durable and provide significant aesthetic
and decorative effects to the structures to which they are applied.
Roof components or coverings as described herein may be made of
cementitious materials and also brick, stone, clay, plastic, wood,
metal, rubber or bituminous materials.
[0007] A typical pitched roofing system includes sheets of wood,
typically plywood or decking material, nailed to the truss rafters
to form a pitched roof deck. Other pitched roof decks may be made
with materials such as steel or concrete. Typically, the pitched
roof deck is overlaid with a roof substrate made of a waterproofing
material. Typically, the waterproofing material forming the roof
substrate is a roll goods membrane or underlayment comprising one
or more plies of asphaltic or modified bitumen impregnated felt
attached to the pitched roof deck. The felt is typically attached
to the pitched roof deck by nails and/or adhesive. Felt is
generally made of wood pulp and rag or of asbestos, polyester or
glass fibers. Self-adhering membranes, commonly referred to as
"peel and stick," may also be used. These membranes are generally
modified bitumen impregnated fiberglass or polyester fibers. Some
pitched roof systems having steel or concrete decks do not require
the use of a waterproof membrane or coating.
[0008] Roof components are primarily secured to the pitched roof
deck with mechanical fasteners. Nails are the primary mechanical
fasteners for securing roof components to a wood deck. Typically,
tile roof components are secured with nails, inserted through holes
in the tile roof component, driven into and through the roof
substrate and wood deck. Mortar is sometimes used in conjunction
with nails to provide holding force of the tile roof component to
the roof deck. In either case, it is undesirable to drive numerous
holes through the roof substrate and wood deck since these nail
holes provide a potential leak path in the pitched roofing system.
High wind loading conditions also affect the roof components
secured with nails. In areas near salt water the effectiveness of
nails is diminished over time due to corrosion of the nails.
Additionally, nails get loose over a period of time. Some decks,
such as concrete or steel decks, cannot be nailed into.
Non-nailable decks (concrete, steel, etc.) use a wire tie or other
cumbersome and expensive system to fasten the roof components to
the pitched roof deck.
[0009] As stated above, mortar or similar binders are often used as
a secondary fastener between tile roof components and the roof
substrate. Using mortar is a slow procedure and labor intensive as
the mortar must first be prepared, typically at ground level, in
buckets which must then be raised to the pitched roof deck, and
then the mortar is applied to the roof substrate. The mortar adds
unnecessary weight to the roofing system. The set-up time of the
mortar increases the time required to form the bond between the
tile roof component and the roof substrate. The installed tile roof
components should not be disturbed until the mortar has set-up as
movement of the tile roof component affects the bond. Furthermore,
the strength of the completed bond between the tile roof component
and the roof substrate can be unsatisfactory. Typically, an
approximate 60-pound tensile load applied transversely to the tile
roof component will break the mortar bond between the tile roof
component and the roof substrate. During high wind loading
conditions, such as that experienced during a hurricane or a
tornado, the tile roof components frequently release from the roof
structure and become life threatening, flying projectiles. During
such events, the tile roof components are widely strewn about and
scattered throughout the area. The flying tile roof components
result in additional danger during these devastating events and
further increase the tremendous burden of clean up after these
catastrophic events.
[0010] Assignee's U.S. Pat. No. 5,362,342 discloses a method of
bonding tile roof components to a roof substrate utilizing
polyurethane foam as the bonding medium. The method includes the
step of applying under low pressure a stream of two component
foamable liquid polyurethane on a prepared roof substrate. The
foamable liquid polyurethane has a density preferably in the range
of one and one-half to two pounds per cubic foot and a reactivity
period in the range of one and one-half to four minutes. The
foamable liquid polyurethane is preferably applied at a rate in the
range of two to three pounds per minute. The tile roof component is
placed into contact with the foamable liquid polyurethane during
the reactivity period of the foamable liquid polyurethane. The bond
between the tile roof components and the roof substrate with the
polyurethane foam is several times increased over the mortar and
mechanical bonds.
[0011] Another type of roof component used is a roof panel,
typically made of metal. Roof panels are often used to form a
standing seam roof. A typical standing seam roof utilizes adjacent
interlocking elongated panels which are affixed at their edges.
Typically, the standing seam roof panels are generally flat with
upstanding interlocking ribs extending the length of the elongated
panel. Separate attachment clips or fasteners spaced along the
standing seam are typically utilized to attach the panel to the
roof deck or substrate. The fasteners, in some instances, include
nails or screws penetrating the roof panel. Problems exist in
trying to secure such panels to a roof so that they survive
substantial wind conditions and the capillary action of water (and
the problems it causes to the underlying roof structure). Roof
panels are available in a variety of sizes, shapes and materials.
For example, some roof panels are approximately 12'' wide and have
a length of 40' while some roof panels have a width of
approximately 36'' and lengths ranging from 2' to 20'. Some roof
panels are "stepped" to create a tile-like appearance and are
commonly referred to as "tile panels." A typical tile panel,
typically made of metal, gives the appearance of rows of
overlapping Spanish tiles without the weight of Spanish tile. A
single 36'' wide by 20' panel covers as much area as 80 tiles at
just a fraction of the weight.
[0012] It is desirable to provide an energy efficient pitched
roofing system at a reasonable cost. Thus, it is desirable to have
a pitched roofing system that provides insulation to reduce energy
consumption. It is also desirable that the method of installation
be a simple operation, non-labor intensive, economical and not
require excessive installation time. It may also be desirable to
minimize the difficulty of precisely aligning and installing the
rows of roof components to assure the most aesthetically pleasing
appearance of the installed roofing system. Additionally, the
pitched roofing system should withstand the long-term effects of
temperature and climatic variations experienced by the pitched
roofing system under normal circumstances.
BRIEF SUMMARY OF THE INVENTION
[0013] One embodiment of the present invention includes an
insulated pitched roofing system and method of installation for a
sloped or pitched roof deck of wood, metal, concrete or other
material. The pitched roofing system according to an embodiment of
the present invention is energy efficient and is particularly
suited to a roof having a 2:12 pitch or greater.
[0014] An insulating component according to an embodiment of the
present invention includes a board or sheet material which is
adhered to the roof deck. Preferably, the sheet material includes a
substantially flat lower surface and an upper surface. The lower
surface is preferably adhered to the roof substrate on the roof
deck with a polymer adhesive. Preferably, the roof components, such
as roof tiles or roof panels, are adhered to the upper surface of
the sheet material with the polymer adhesive.
[0015] An alternative embodiment of the present invention includes
the sheet material having a contoured upper surface corresponding
with the tile profile to be installed. The contoured upper surface
provides guidance in properly placing and aligning the roof tiles
on the roof for ease of installation and a more pleasing
appearance.
[0016] The method of installing the pitched roofing system
according to an embodiment of the present invention is a simple
operation, non-labor intensive, economical and does not require
excessive installation time. The pitched roofing system will
withstand the long-term effects of temperature variations and
climatic conditions experienced by the pitched roofing system under
normal circumstances.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0017] The objects, advantages, and features of the invention will
become more apparent by reference to the drawings which are
appended hereto and wherein like numerals indicate like parts and
wherein an illustrated embodiment of the invention is shown, in
which:
[0018] FIG. 1 is a perspective view of a typical roof tile that can
be used with an embodiment of the pitched roofing system of the
present invention;
[0019] FIG. 2 is a perspective view of a pitched roof deck having a
roof substrate applied to the roof deck and a layer of insulating
sheets applied to the roof substrate;
[0020] FIG. 3 is a perspective view of a portion of the pitched
roofing system with a lower row of roof tiles being adhered to the
insulating sheet;
[0021] FIG. 4 is a perspective view of a portion of the pitched
roofing system with an upper row of roof tiles overlapping the
lower row of roof tiles;
[0022] FIG. 5 is a view taken along lines 5-5 of FIG. 4;
[0023] FIG. 6 is perspective view of a contoured insulating sheet;
and
[0024] FIG. 7 is a perspective view of a building illustrating an
embodiment of the present invention having a plurality of roof
panels.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT
[0025] The insulated pitched roofing system and method of
installing same, generally designated as 100, will now be described
in greater detail with specific reference to the drawings.
Referring to FIG. 1, the pitched roofing system 100 according to a
first embodiment of the present invention includes a roof
component, designated generally as 10. The roof component 10 shown
in perspective view in FIG. 1 is known as a semi-circular roof
tile. It is to be understood that the system and method of the
present invention 100 is not limited to semi-circular roof tiles.
Rather, the system and method 100 can include roof components 10 of
other types and configurations. For example, flat roof tiles and
reverse curve roof tiles are just a few of the other types that can
be used with the system and method 100. Typically, the tile
components 10 are made from cementitious or clay materials. It is
also to be understood that the system and method of the present
invention 100 is not limited to clay or cementitious roof tiles 10
but is also applicable to roof components 10 made from other
materials including, but not limited to, brick, stone, plastic,
wood, metal, rubber, or bituminous materials. It is additionally to
be understood that roof components 10 also include roof panels as
shown in FIG. 7, including tile panels.
[0026] As shown in FIGS. 1 and 3, the roof component 10 typically
includes an interlocking connection at the first and second
longitudinal edges 12 and 14, respectively, of the roof component
10. Referring to FIG. 3, the second edge 14 of the first roof
component 10 mates with the first edge 12 of an adjoining second
roof component 10'. This type of interlocking connection for roof
components 10, such as roof tiles, is well known in the art. The
tile roof component 10 as shown in FIG. 1 includes a first pan
portion 13 and a second pan portion 15. Typically, the pan portions
13 and 15 extend the length of the tile roof component 10. It is to
be understood that the pan portions 13 and 15 are part of the
illustrated roof component 10 shown in FIGS. 1, 3 and 4, but are
not essential to the invention.
[0027] A pitched roof deck, generally designated as 50, is shown in
FIG. 2. Typically, the pitched roof deck 50 is comprised of sheets
of plywood or decking material 52 nailed to a plurality of truss
rafters 54 or installed to other structural members or structural
supports. The decking material 52 is typically in 4' by 8' sheets.
Although not shown, the sheets of decking material 52 are
positioned end to end and side to side. Typically, a plurality of
nails is driven through the decking material 52 into the truss
rafters 54. The truss rafters 54 are typically on 24'' or 16''
centers. A sheet of decking material 52 is thus nailed to
approximately 5 or 7 truss rafters 54. It is to be understood that
several truss rafters 54 have been omitted for clarity in FIG. 2.
It is also to be understood that the roof deck 50 may alternatively
be constructed of concrete, metal or other material.
[0028] Preferably, a roofing substrate 20 forming a waterproof
coating is applied and preferably bonded to the upper surface of
the decking material 52. The roofing substrate 20 can be a felt,
commonly used in the roofing industry. The felt is a roll goods
membrane that is fastened to the decking material 52, typically
with mechanical fasteners such as nails and/or bonded to the
decking material with, for example, tar or bitumen. The felt is
typically applied along the length of the roof with an adjacent row
of the felt overlapping the edge of the prior row of felt. The
roofing substrate 20 protects against rain and moisture coming into
contact with and passing through the pitched roof deck 50. It is to
be understood that in some circumstances the roofing substrate 20
may not be desired or necessary for the present invention.
[0029] Referring to FIG. 2, an insulating component 22 is shown in
position on the pitched roof deck 50. Preferably, the insulating
component 22 is a board or sheet material. Preferably the
insulating component 22 is made from an expanded rigid polystyrene
plastic material such as Styrofoam.RTM. material. Styrofoam.RTM. is
the registered trademark of Dow Chemical Company. The insulating
component 22 is preferably adhered to the roofing substrate 20, if
used, or to the decking material 52 of the roof deck 50 if the
roofing substrate 20 is not used. Preferably, the insulating sheet
material 22 includes a substantially flat lower surface and an
upper surface 22a. In an embodiment of the present invention, the
lower surface is adhered to the roofing substrate 20 or the decking
material 52 of the roof deck 50 with a polymer adhesive 40,
preferably polyurethane, described in greater detail below. It is
to be understood that the amount of adhesive required to adhere the
insulating sheet material 22 to the roofing substrate 20 or roof
deck 50 will depend upon the installer, the bonding strength of the
materials and the environmental and/or load conditions to which the
system is being designed. A plurality of insulating sheets 22 of
substantially uniform size are positioned in abutting contact with
each other on the roof deck 50 as shown in FIG. 2. The insulating
sheets 22 are preferably sized for convenience of handling. For
example, the sheets may be 4' by 8', or 4' by 4', or sized in
relation to the roof components 10 to be attached thereon as will
be explained below. Additionally, it is to be understood that the
roofing installer may prefer to place the insulating sheets 22 on
substantially the entire face of the pitched roof deck 50 prior to
the installation of the roof components 10 or may choose to install
the insulating sheets 22 on only a portion of the deck face and
then installing the roof components 10 on the installed insulating
sheets prior to installing more insulating sheets 22.
Alternatively, the roof components 10 may be installed as each
insulating sheet 22 is installed. Yet another alternative is to
install a row of the insulating sheets 22 prior to installing the
roof components 10.
[0030] The roof components 10 are preferably adhered to the upper
surface 22a of the sheet material 22 with an adhesive, such as the
polymer adhesive 40. Preferably, the polymer adhesive 40 is a
polyurethane described in greater detail below. A method of
attaching the roof components 10 to a roofing substrate and a
typical polymer adhesive 40 are disclosed in assignee's U.S. Pat.
No. 5,362,342, issued to Murray et al., which is incorporated by
reference. However, it is to be understood that the present
invention is not limited to the method and adhesive disclosed in
U.S. Pat. No. 5,362,342.
[0031] One method of attaching the roof components 10 with the
polymer adhesive 40 is shown in FIGS. 3-5. Referring to FIG. 3, the
roof components 10 are installed in rows beginning along the lower
edge of the roof. One or more pads or paddies 18 are located at or
adjacent the position where the first pan portion 13 of the roof
component 10 will be situated on the insulating sheet 22 adhered to
the roofing substrate 20. The roof component 10 is then adhered to
the insulating sheet 22. Referring to FIG. 3, a worker places one
or more paddies 18 of the polymer adhesive 40 on the insulating
sheet 22 at a location at which the roof component 10' is to be
applied. The roof component 10' is placed adjacent to the
previously installed roof component 10 so that the first edge 12 of
the second roof component 10' overlaps and interlocks the second
edge 14 of the first roof component 10. The first pan portion 13 of
the roof component 10 is positioned in and above the paddy or
paddies 18 of polymer adhesive 40 during the reactivity period of
the polymer adhesive 40. Due to the interlocking connection of
adjacent roof components 10 as shown in FIG. 3, the polymer
adhesive 40 is not required beneath the second pan portion 15 of
the roof component 10. One or more paddies 18 beneath the second
pan portion 15 may be used to obtain an even greater bond between
the insulating sheet 22 and the roof component 10, if desired. It
is to be understood that the above described method may be
preferred for the tile shape shown in FIGS. 1, 3 and 4, although
other arrangements or placement and amounts of adhesive 40 can be
used. Further, it is to be understood that other tile shapes used
with the present invention may require other arrangements and/or
placement of the adhesive 40 to bond the roof component 10 to the
insulating sheet 22.
[0032] According to one embodiment of the present invention, the
polymer adhesive 40 may be a foamable or a non-foamable polymer
adhesive. Preferably, the polymer adhesive 40 is a polyurethane
adhesive, and more preferably a plural component polyurethane
adhesive. The significant advantage of the plural component
polyurethane adhesive is being able to walk on the installed roof
components 10 shortly after the roof components 10 have been
installed without affecting the bond between the roof component 10
and insulating sheet 22. The reactivity period or rise time of the
plural component liquid polyurethane adhesive 40 of the present
invention is preferably about one-half to about ten minutes and
most preferably about one and one-half to about four minutes. It is
important that the roof component 10 be properly placed during the
reactivity period to achieve the required bonding of the roof
component 10 to the insulating sheet 22. During the reactivity
period, a foamable polyurethane adhesive 40 is an expanding foam,
which will fill gaps and imperfections. The resulting foam provides
excellent bonding between the roof component 10 and the insulating
sheet 22 due to the adhesive properties of the urethane. It has
been found that a reactivity period of less than about one-half
minute makes it difficult to timely place the roof component 10
during the reactivity period.
[0033] The foamable liquid polyurethane 40 is preferably a froth
foam. Froth foam chemistry is well known in the art of urethane
foams. The froth foam may be formed by using blowing agents such as
hydrogenated chlorofluorocarbon R22 (HCFC-R22), hydrogenated
fluorocarbon 134A (HFC-134A), or chlorofluorocarbon R12 (CFC-R12).
Preferably, the froth foam 40 is formed by using the hydrogenated
blowing agents HCFC-R22 or HFC-134A, and not CFC-R12 due to
CFC-R12's reported deleterious effects to the earth's ozone
layer.
[0034] Preferably, the froth foam 40 has a consistency similar to a
foamy shaving cream. The froth foam is preferable over other types
of foams because it can be neatly and accurately dispensed without
blowing or overspraying onto other areas of the roof deck or onto
the outer surface of adjacently installed roof components 10. The
preferred liquid polyurethane 40 with its shaving cream consistency
does not run when placed onto a steeply pitched roof, but remains
where it is installed on the insulating sheet 22. This ensures that
the adhesive bond will be formed at the appropriate locations of
the roof component 10. Additionally, the froth foam 40 begins
expanding immediately upon application to the insulating sheet 22
and results in a firm bond with the underside of the roof component
10.
[0035] The liquid polyurethane 40 preferably has a density of about
one to about eight pounds per cubic foot. It may be desirable to
minimize the density of the liquid polyurethane 40 to minimize the
weight on the roof while still providing an excellent bonding of
the roof component 10 to the insulating sheet 22. It has been found
to be most preferable to have a foam density of about one and
one-half to about two pounds per cubic foot. The application rate
of the liquid polyurethane 40 is preferably about one to about six
pounds per minute and most preferably about two to about three
pounds per minute.
[0036] Referring to FIGS. 4 and 5, a second row of roof components
10 is shown overlapping the lower row of roof components 10. As
shown in FIG. 5, the first pan portion 13 does not rest on the
insulating sheet 22 along its entire length. The first pan portion
13 at the highest end of roof component 10 comes into contact or
very near contact with the insulating sheet 22 but moves gradually
away from the insulating sheet 22 at the lowest end where it
overlaps the lower adjacent roof component 10. The foamable liquid
polyurethane 40 expands and fills the gaps between the insulating
sheet 22 and the first pan portion 13. The excess foam continues
expanding and provides further bonding with adjacent surface areas
of the roof component 10 as shown in FIGS. 3-5. A thin layer of
foam may be present between the insulating sheet 22 and the first
pan portion 13 at the highest end of the roof component 10
depending on the placement of the paddy or paddies 18.
[0037] Referring to FIG. 5, the expanding foam 40 also provides a
bond between the upper roof component 10 and the lower roof
component 10 at the overlapping portion where the expanding foam
can fill any gap between the two roof components 10. This further
enhances the overall bonding capacity of the roof components 10 to
the insulating sheet 22.
[0038] As shown in FIG. 6, a second embodiment of the insulating
sheet 220 may include a contoured upper surface 220a as opposed to
the generally flat upper surface 22a of the insulating sheet 22.
The contoured upper surface 220a preferably corresponds with the
lower profile of the roof component 10 to be installed thereon. The
contoured upper surface 220a provides guidance in properly placing
and aligning the roof tiles 10 on the pitched roof. A panel having
a contoured upper surface is presently available in Japan and is
known as a "Yuka panel." The Yuka panel is currently used in Japan
with a trowel-applied paste material providing the bonding medium
of the Yuka panel to the substrate as well as the bonding medium of
the roof tile 10 to the Yuka panel. In the present invention the
polymer adhesive 40 is used to adhere the roof tile 10 to the
contoured upper surface 220a of the insulating sheet 220. The Yuka
panel is typically sized for placement of approximately four rows
of approximately four tiles in each row. The contoured surface 220a
aids in ensuring that the roof tiles 10 are properly placed to
provide a more pleasing aesthetic appearance. The panel 220
preferably has a thickness sufficient to provide enhanced
insulative properties. For example, the panel thickness may be one
or two inches thick, but may also depend on roof tile shape if
using the contoured panel 220.
[0039] FIG. 7 shows an embodiment of the present invention in which
the roof components 10 are roof panels. The roof panels 10 are
preferably adhered to a plurality of installed insulating sheets 22
on a pitched roof as shown in FIG. 2. Although FIG. 7 shows single
roof panels 10 spanning the length from the ridgeline to the eve of
the roof, it is to be understood that the spanned length could
comprise several similarly aligned roof panels 10. Additionally, it
is to be understood that the roof panels 10 can be tile panels.
Typically, tile panels have a tile-like appearance. The roof panels
10 are typically made of metal and include interlocking edges. As
described above, preferably the lower surface of the roof panels 10
are adhered to the upper surface of the insulating sheets 22 with
the polymer adhesive.
[0040] It is to be understood that the present invention is an
insulated pitched roofing system and method 100 that can be used on
pitched roof decks 50 made of various materials, including but not
limited to wood, metal and concrete. The system 100 according to an
embodiment of the present invention includes an insulating sheet
22, 220 adhered with a polymer adhesive 40 to the pitched roof deck
50 or the roof substrate 20 attached to the pitched roof deck 50.
The roof components 10 are adhered with the polymer adhesive 40 to
the insulating sheet 22, 220. The upper surface 220a of the
insulating sheet 220 may be contoured to aid in properly placing
the roof components 10. The improved roofing system 100 provides a
well insulated roof for energy efficiency.
[0041] A few embodiments of a pitched roofing system and method of
installing same according to the present invention have thus been
set forth. However, the invention should not be unduly limited to
the foregoing, which has been set forth for illustrative purposes
only. Various modifications and alterations of the invention will
be apparent to those skilled in the art, without departing from the
true scope of the invention.
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