U.S. patent application number 11/991316 was filed with the patent office on 2009-05-28 for roof system.
This patent application is currently assigned to KINGSPAN RESEARCH AND DEVELOPMENTS LIMITED. Invention is credited to James Carolan, Gregory Flynn.
Application Number | 20090133339 11/991316 |
Document ID | / |
Family ID | 37232401 |
Filed Date | 2009-05-28 |
United States Patent
Application |
20090133339 |
Kind Code |
A1 |
Carolan; James ; et
al. |
May 28, 2009 |
Roof System
Abstract
A roof system comprises a lower layer of composite insulating
panels (2), a protective barrier layer (3) and an upper decorative
layer (4) which provides a roof garden. The panels (2) comprise a
profiled internal sheet (5), a generally flat external sheet (6)
with an insulating core (7) therebetween. The panels (2) provide a
mechanically strong roof structure to support the garden layer (4).
The panels (2) are protected by a roof barrier membrane (11).
Inventors: |
Carolan; James; (County
Cavan, IE) ; Flynn; Gregory; (County Louth,
IE) |
Correspondence
Address: |
JACOBSON HOLMAN PLLC
400 SEVENTH STREET N.W., SUITE 600
WASHINGTON
DC
20004
US
|
Assignee: |
KINGSPAN RESEARCH AND DEVELOPMENTS
LIMITED
County Cavan
IE
|
Family ID: |
37232401 |
Appl. No.: |
11/991316 |
Filed: |
September 6, 2006 |
PCT Filed: |
September 6, 2006 |
PCT NO: |
PCT/IE2006/000094 |
371 Date: |
February 29, 2008 |
Current U.S.
Class: |
52/173.1 |
Current CPC
Class: |
Y02A 30/254 20180101;
Y02B 80/32 20130101; E04D 7/00 20130101; E04D 11/002 20130101; E04D
3/355 20130101; E04D 3/352 20130101; E04B 7/22 20130101 |
Class at
Publication: |
52/173.1 |
International
Class: |
E04B 7/18 20060101
E04B007/18; E04B 7/00 20060101 E04B007/00 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 6, 2005 |
IE |
2005/0582 |
Claims
1-29. (canceled)
30. A roof system comprising a support layer comprising a composite
insulated panel of the type having a profiled sheet and a generally
flat sheet with an insulating core between the profiled sheet and
the flat sheet; and a barrier layer applied to the generally flat
sheet of the support layer for reception of an upper decorative
layer.
31. The system as claimed in claim 30 wherein the barrier layer
comprises a root barrier membrane.
32. The system as claimed in claim 30 wherein the decorative layer
comprises a growing medium for plants and the like.
33. The system as claimed in claim 30 wherein the decorative layer
is arranged to cover only a portion of the top face of the
composite insulating panels.
34. The system as claimed in claim 30 wherein the decorative layer
comprises a water receiving layer.
35. The system as claimed in claim 30 wherein the decorative layer
comprises stones and/or sand and/or gravel.
36. The system as claimed in claim 30 wherein the decorative layer
comprises a drainage, aeration and water storage layer.
37. The system as claimed in claim 36 wherein the drainage,
aeration and water storage layer comprises a top face and a
plurality of recessed wells.
38. The system as claimed in claim 37 wherein the recessed wells
project downwardly to contact an underlying surface and to space
the top face apart from the underlying layer.
39. The system as claimed in claim 30 wherein the decorative layer
comprises a permeable membrane.
40. The system as claimed in claim 39 wherein the permeable
membrane is laid on top of the drainage, aeration and water storage
layer.
41. The system as claimed in claims 39 wherein the permeable
membrane comprises a geotextile fabric.
42. The system as claimed in claim 32 wherein the planting medium
comprises soil or peat or sand, or any suitable mixture
thereof.
43. The system as claimed in claim 30 comprising drainage
means.
44. The system as claimed in claim 30 wherein the panels are
connected to supporting external and/or internal walls.
45. The system as claimed in claim 30 wherein the root barrier
layer is connected to the panels by adhesive or other suitable
fixing means.
46. The system as claimed in claim 30 wherein the barrier layer is
connected to the external walls.
47. The system as claimed in claim 44 comprising a metal coping for
connection to the external walls.
48. The system as claimed in claim 30 comprising a decorative layer
retention device to define the perimeter of the decorative
layer.
49. The system as claimed in claim 30 wherein the profiled sheet of
the composite insulated pane defines a plurality of channels
extending longitudinally along the length of the panel.
50. The system as claimed in claim 49 wherein the channels are of
generally trapezoidal shape comprising a generally flat base and
side walls which extend from and diverge outwardly from the
base.
51. The system as claimed in claim 50 wherein the side walls of the
trapezoidal formations are stepped side-walls.
52. The system as claimed in claim 50 wherein the profiled sheet
has transversely extending reinforcing ribs.
53. The system as claimed in claim 30 wherein the profiled sheet
has a first overlap portion on one side and a second overlap
portion on the opposite side, the first overlap portion being
substantially free of insulating core, the side edge of the
insulating core at the first overlap portion having a first
inclined wedge face and the side edge of the insulating core at the
second overlap portion having a second inclined wedge face which is
oppositely directed to the first inclined wedge face at the first
overlap portion, the overlap portions and the wedge faces of the
insulating core of adjacent like panels being interengageable on
assembly.
54. The system as claimed in claim 53 wherein the profiled sheet
overlap portions are defined by part trapezoidal portions.
55. The system as claimed in claim 30 wherein the generally flat or
second sheet has a second sheet first overlap portion on one side
and a second sheet second overlap portion on the opposite side.
56. The system as claimed in claim 55 wherein the overlap portions
comprise profiled portions of the external sheet.
57. The system as claimed in claim 55 wherein the second sheet has
an outer male projecting part and an inner recess part on one side,
and a corresponding outer recess part and projecting inner male
part respectively on the opposite side of the panel.
Description
INTRODUCTION
[0001] The invention relates to a roof having an upper decorative
layer.
[0002] In one current approach a decorative layer such as a garden
is installed onto a flat roof. However, there are several problems
with conventional systems including excess loading on the roof,
water retention in periods of rainfall and a risk of water damage
to the roof or roof leaks. In most cases the use of such decorative
roof systems is confined to concrete roofs. There is a need for an
improved roof system which addresses such problems.
STATEMENTS OF INVENTION
[0003] According to the invention there is provided a roof system
comprising a support layer comprising a composite insulated panel
of the type having a profiled sheet and a generally flat sheet with
an insulating core between the profiled sheet and the flat sheet;
and a barrier layer applied to the generally flat sheet of the
support layer for reception of an upper decorative layer.
[0004] In one embodiment, the barrier layer comprises a root
barrier membrane.
[0005] In one case the decorative layer comprises a growing medium
for plants and the like.
[0006] The decorative layer may be arranged to cover only a portion
of the top face of the composite insulating panels.
[0007] In one embodiment the decorative layer comprises a water
receiving layer.
[0008] The decorative layer may comprise stones and/or sand and/or
gravel.
[0009] In one embodiment the decorative layer comprises a drainage,
aeration and water storage layer. The drainage, aeration and water
storage layer may comprise a top face and a plurality of recessed
wells. In one embodiment the recessed wells project downwardly to
contact an underlying surface and to space the top face apart from
the underlying layer.
[0010] In one embodiment the decorative layer comprises a permeable
membrane. The permeable membrane may be laid on top of the
drainage, aeration and water storage layer. In one case the
permeable membrane comprises a geotextile fabric.
[0011] In one embodiment the planting medium comprises soil or peat
or sand, or any suitable mixture thereof.
[0012] In one embodiment the system comprises drainage means.
[0013] In one arrangement the panels are connected to supporting
external and/or internal walls.
[0014] The root barrier layer may be connected to the panels by
adhesive or other suitable fixing means.
[0015] In one embodiment the barrier layer is connected to the
external walls.
[0016] The system may comprise a coping, typically of metal for
connection to the external walls.
[0017] In one embodiment the system comprises a decorative layer
retention device to define the perimeter of the decorative
layer.
[0018] In one embodiment the profiled sheet of the composite
insulated panel defines a plurality of channels extending
longitudinally along the length of the panel.
[0019] The channels may be of generally trapezoidal shape
comprising a generally flat base and side walls which extend from
and diverge outwardly from the base.
[0020] In one case the side walls of the trapezoidal formations are
stepped side-walls.
[0021] The profiled sheet may have transversely extending
reinforcing ribs.
[0022] In one embodiment the profiled sheet has a first overlap
portion on one side and a second overlap portion on the opposite
side, the first overlap portion being substantially free of
insulating core, the side edge of the insulating core at the first
overlap portion having a first inclined wedge face and the side
edge of the insulating core at the second overlap portion having a
second inclined wedge face which is oppositely directed to the
first inclined wedge face at the first overlap portion, the overlap
portions and the wedge faces of the insulating core of adjacent
like panels being interengageable on assembly.
[0023] The profiled sheet overlap portions may be defined by part
trapezoidal portions.
[0024] In one embodiment the generally flat or second sheet has a
second sheet first overlap portion on one side and a second sheet
second overlap portion on the opposite side. The overlap portions
may comprise profiled portions of the external sheet.
[0025] In one embodiment the second sheet has an outer male
projecting part and an inner recess part on one side, and a
corresponding outer recess part and projecting inner male part
respectively on the opposite side of the panel.
[0026] According to the invention there is provided a roof system
having a lower layer comprised of one or more composite insulated
panels and a separate upper decorative layer.
[0027] In one embodiment the roof system comprises an intermediate
protective covering layer between the panels and the decorative
layer.
[0028] In another embodiment the protective covering layer
comprises an impermeable roof membrane.
[0029] In a further embodiment the protective covering layer
further comprises a membrane protection and root barrier.
[0030] In one embodiment the decorative layer comprises multiple
layers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The invention will be more clearly understood from the
following description thereof, given by way of example only, with
reference to the accompanying drawings, in which:--
[0032] FIG. 1 is a cross-sectional view of a roof system according
to the invention;
[0033] FIG. 2 is detailed cross-sectional view of the roof system
of FIG. 1;
[0034] FIG. 3 is an enlarged view of a panel joint detail of the
roof system of FIGS. 1 and 2;
[0035] FIG. 4 is a cross-sectional view of another roof system
according to the invention;
[0036] FIG. 5 is detailed cross-sectional view of the roof system
of FIG. 4;
[0037] FIG. 6 is a perspective view of one sheet of a panel used in
the roof system;
[0038] FIG. 7 is a plan view of the panel sheet of FIG. 6; and
[0039] FIGS. 8(a) to 8(c) are cross-sectional views of various
alternative panels of the roof system;
DETAILED DESCRIPTION OF THE DRAWINGS
[0040] Referring to the drawings, there is illustrated a roof
system 1 comprising a lower layer of panels 2, and a protective
barrier layer 3. An upper decorative layer 4, in this case
comprising a planting medium suitable for planting and growing
vegetation is installed thereon.
[0041] Referring to the roof system of FIGS. 1 and 2 the decorative
layer 4 is comprised of multiple layers, including a water
receiving layer. The decorative layer may be arranged to cover only
a portion of the top face of the layer of composite insulating
panels. Alternative decorative layers may be installed for example,
a layer of stones, sand or gravel or a mixture thereof or a water
feature.
[0042] The panels 2 comprise a profiled internal sheet 5, a
generally flat external sheet 6, and an insulating core 7
therebetween. The sheets are in this case of light gauge steel and
the core is of a polyisocyanurate foam material. The panels 2
further comprise corresponding engagement means 8 to enable
interengagement of adjacent panels on assembly. The engagement
means 8 provides for secure interconnection of the panels 2
providing a mechanically strong roof structure capable of
supporting a heavy load.
[0043] In this case, the profiled sheet 5 is comprised of a
plurality of ridge portions 19 and valley portions 20 and the
valley and ridge portions are of generally trapezoidal form.
[0044] Referring to FIG. 3, in this case, the external sheet 6
comprises an external male projecting part 21 and an internal
recess part 22 on one side for engagement on assembly with a
corresponding external recess part 23 and projecting internal male
part 24 respectively on the opposite side of the panel. At least a
portion of the side edges 25 and 26 of the insulating core 7
between the joint forming portions of the external sheet and
internal sheet has an inclined profile and the inclined profiles of
the opposite side edges of the insulating core 7 form oppositely
directed wedge faces. A side edge of the insulating core of one
panel is matched with the opposite side edge of an adjacent panel
on assembly.
[0045] In use, the panels 2 are supported between an external wall
30 and other supporting walls. When the panels 2 are assembled, the
protective layer 3 is laid thereon. The protective layer 3
comprises a roof membrane 10 and a membrane protection and root
barrier 11. The roof membrane 10 is installed onto the upwardly
facing external sheet 6 of the panels 2 and the membrane protection
and root barrier 11 is laid thereon.
[0046] When the roof panels 2 are thus covered and protected, the
decorative layer 4 is installed. Referring to FIGS. 1 and 2 in this
case the decorative layer 4 comprises, from the base upwards, a
drainage aeration and water storage layer 12, a further roof
barrier layer 13, and a layer of a growing medium 14. Vegetation 15
is planted in the growing medium 14.
[0047] The roof membrane layer 10 serves to protect the surface of
the panels and to stop any water penetration. The roof membrane 10
is an impermeable membrane for example, of polyvinylchloride (PVC),
bitumen or a Thermoplastic PolyOlefin (TPO) type material. Suitable
materials include for example, Trocal, Sarna, or Flag. However, it
will be appreciated that any suitable material may be used for
example a plastics or polymer material.
[0048] The membrane protection and root barrier layer 11 is
comprised of heat welded PVC, TPO or high density polyethylene and
serves to prevent roots from damaging the water proofing layer.
[0049] The roof membrane layer 10 and/or the membrane protection
and roof barrier layer 11 are applied to the panels 2 on site. In
some cases a single root barrier layer is provided on the generally
flat upwardly facing sheet of the panels.
[0050] The drainage aeration and water storage layer 12 comprises
means to control water levels in the planting medium 14. In this
case the layer 12 comprises an upper face 17 having a plurality of
recessed wells 16. The wells 16 provide water storage and drainage.
When the drainage aeration and water storage layer 12 is laid down,
the recessed wells 16 project downwardly contact the underlying
support and to space the upper face apart from the underlying
surface to enable the circulation of air and/or to provide a
passage for the drainage of excess water if required.
[0051] The roof barrier layer 13 comprises a permeable membrane
which serves to prevent soil from the planting layer clogging the
drainage aeration and water storage layer. The roof barrier layer
13 is comprised of a geotextile filter fabric, for example.
[0052] A suitable planting medium layer 14 is then laid on top of
the membrane 13. The planting medium may be comprised of various
proportions of soil or sand as required depending on the type of
vegetation to be planted.
[0053] In the embodiment illustrated, the roof system 1 is
installed by connection to the supporting wall 30. The roofing
membrane and root barrier are connected to roof panels 2 and to the
wall by suitable fixing means, for example by adhesive means or
mechanical fixing. The roof membrane and barrier are installed so
that they extend over the top face of the panels 2 and upwardly at
external walls 30 at the sides of the roof to define a sealed
recessed area suitable for planting.
[0054] In the embodiment shown, a metal coping 31 is connected to
the top of the external wall 30.
[0055] A planting medium or soil retention element 33 is installed
to define the perimeter of the planting area and to retain the
planting medium 14 in that area. A ballast 32, for example of
gravel is installed between the soil retention element 33 and the
edge of the roof.
[0056] Roof sealing is provided by the composite insulated panels
2. Drainage is handled through the drainage layer.
[0057] An inner facing such as of plywood or plasterboard 34 may be
installed below the roof panels.
[0058] Referring to FIGS. 4 and 5 there is illustrated another roof
system of the invention in which parts similar to those illustrated
in FIGS. 1 and 2 are assigned the same reference numerals. In this
case the decorative layer is an extensive garden layer which has
minimum maintenance and water requirements. Such systems generally
use Alpine plants such as Sedums. The system is of simpler
construction than the intensive system described above.
[0059] Referring to FIGS. 6 to 8, the preformed composite panels 1
used in the roofing systems of the invention are shown in more
detail. The profiled sheet 5 has a plurality of generally
trapezoidal formations 30 each having a generally flat base part 31
and a pair of upwardly extending and diverging side walls 32.
Stepped back intermediate portions 33 are located between the
trapezoidal formations 30. For enhanced structural strength the
side walls 32 of the trapezoidal formations are of stepped form.
Transversely extending reinforcing ribs 35 are provided in the
intermediate portions 33 to again enhance structural
performance.
[0060] The profiled sheet 5 has a first side overlap portion 40 on
one side and a second side overlap portion 41 on the opposite side.
The first overlap portion 40 is substantially free of insulating
core 7 and the side edge of the insulating core at the first
overlap portion has a first inclined wedge face 43. At the second
side overlap portion 41 the side edge of the insulating core has a
second inclined wedge face 44 which is oppositely directed to the
first inclined wedge face 43 so that the wedge faces 43, 44 of
adjacent like panels are interengagable on assembly.
[0061] The generally flat sheet 6 may have a first overlap portion
50 on one side and a second overlap portion 51 on the opposite
side. The first overlap portion 50 comprises an outer male
projecting part 52 and an inner recess part 53. The second overlap
portion 51 comprises an outer recess part 54 and an inner male
projecting part 55 which are interengagable with the outer male
projection 52 and the inner recess part 53 of an adjacent like
panel, on assembly.
[0062] Various alternative constructions of composite panels to
suit various requirements used in roofing systems of the invention
are illustrated in FIGS. 8(a) to 8(c). In one case (FIG. 8(a))
there is no engagement features formed in the sheet 6.
[0063] The roof system of the invention has the advantages of
providing a finished insulated roof. The layer of panels defining
the lower layer of the roof system are of large span and have a
high load carrying capability enabling the installation of a load
for example a decorative layer, or a planted medium thereon. It is
possible to have a membrane external finish which also acts as a
water permeability barrier. The span of the roof depends on the
size of the panels used. However, it is noted that the panels have
excellent structural strength and may be connected across a wide
span without the need for additional/intermediate structural
support.
[0064] The system of the invention has further advantages including
the following: [0065] visually attractive with a wide range of
possible flower/foliage effects [0066] low maintenance with little
or no artificial irrigation requirements [0067] improved rainwater
management, volume and rate of rainwater run off from the roof is
reduced dramatically [0068] improved building thermal performance,
the building is insulated from heat loss in the winter and heat
gain in the summer [0069] reduction in sound transmission through
the roof [0070] improvement in air quality by removal of carbon
dioxide, release of oxygen and water vapour, deposition of
particulate pollutants and absorption of organic volatiles [0071]
reduction of urban heat island effect [0072] provision of habitat
for wildlife
[0073] The invention is not limited to the embodiments hereinbefore
described which may be varied in construction and detail.
* * * * *