U.S. patent application number 13/497710 was filed with the patent office on 2012-09-13 for roof panel.
This patent application is currently assigned to Kingspan Holdings (IRL) Limited. Invention is credited to Donal Curtin, Donal McCullagh, Peter Simko.
Application Number | 20120227343 13/497710 |
Document ID | / |
Family ID | 43242887 |
Filed Date | 2012-09-13 |
United States Patent
Application |
20120227343 |
Kind Code |
A1 |
Curtin; Donal ; et
al. |
September 13, 2012 |
ROOF PANEL
Abstract
A roof panel (1) for use in forming a low pitch or flat roof
comprises a profiled inner liner or decking sheet (2), an outer
waterproof membrane (3) and a body (4) of insulation between the
inner liner (2) and outer membrane (3). The membrane liner sheet
(3) has a backing such as a fleece or scrim to aid adhesion of the
membrane (3) to the foam body. The membrane (3) comprises a side
lap (5) extending sidewardly of at least some of the marginal edges
of the body (4). The inner liner (2) comprises joint formations for
forming a nested side lap joint between adjacent panels. The joint
formations comprise a first joint formation (20) at one edge of the
liner (2) and a second joint formation (21) on an opposite edge of
the panel. The first and second joint formations (20, 21) of
adjacent panels are adapted to interengage on assembly and are
clinched together using a clinching tool (22) to form a clinched
joint (25). The first joint formation (20) comprises a liner
extension which is shaped to define a recess. There is an inturned
liner leg and a return leg which define the liner recess
therebetween. The second liner formation (21) comprises a liner
extension which is shaped to define a projection which is engagable
in the recess defined by the first liner extension (20). The liner
projection is defined by an inturned liner leg which has a return
lip to reinforce the projection. On assembly of adjacent panels on
site, the liner formations (20), (21) are inter-engaged ed and
clinched together. A foam filler (30) is provided at the joint.
Inventors: |
Curtin; Donal; (Jessup,
MD) ; Simko; Peter; (Caledon, CA) ; McCullagh;
Donal; (Caledon, CA) |
Assignee: |
Kingspan Holdings (IRL)
Limited
Kingscourt
IE
|
Family ID: |
43242887 |
Appl. No.: |
13/497710 |
Filed: |
October 18, 2010 |
PCT Filed: |
October 18, 2010 |
PCT NO: |
PCT/IE2010/000060 |
371 Date: |
May 30, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61272658 |
Oct 16, 2009 |
|
|
|
Current U.S.
Class: |
52/309.4 ;
52/309.1; 52/408; 52/523 |
Current CPC
Class: |
E04D 3/352 20130101;
E04D 3/358 20130101 |
Class at
Publication: |
52/309.4 ;
52/523; 52/408; 52/309.1 |
International
Class: |
E04D 1/34 20060101
E04D001/34; E04C 2/20 20060101 E04C002/20; E04B 1/66 20060101
E04B001/66 |
Claims
1-29. (canceled)
30. A roof panel for forming a low pitch or a flat roof, the roof
panel comprising: an inner liner; an outer weatherproof membrane; a
body of insulating material between the inner liner and the outer
membrane; wherein the inner liner comprises joint formations for
forming a nested side lap joint between adjacent panels.
31. The roof panel as claimed in claim 30 wherein the joint
formations are adapted for clinching.
32. The panel as claimed in claim 30 wherein the joint formations
comprise a first joint formation on one edge of the liner and a
second joint formation on an opposite edge of the liner, the first
liner formation of one panel being adapted for interengaging and
for clinching with a second liner form of an adjacent panel.
33. The panel as claimed in claim 32 wherein the first liner
formation comprises a liner extension which is shaped to define a
recess.
34. The panel as claimed in claim 33 wherein the liner comprises an
inturned leg and a return leg which define the liner recess
therebetween.
35. The panel as claimed in claim 32 wherein the second liner
formation comprises a liner extension which is shaped to form a
liner projection for locating in the liner recess of an adjacent
panel.
36. The panel as claimed in claim 35 wherein the liner comprises an
inturned leg which defines the liner projection.
37. The panel as claimed in claim 36 wherein the liner projection
has a return lip to reinforce the projection.
38. The panel as claimed in claim 30 comprising a fastener for
fastening the panel to a support such as a purlin.
39. The panel as claimed in claim 38 wherein the fastener is a
self-coring fastener.
40. The panel as claimed in claim 30 comprising a filler for
location in the nested side lap joint forming portions of the inner
liner.
41. The panel as claimed in claim 40 wherein the filler is of
insulation material.
42. The panel as claimed in claim 30 wherein the membrane comprises
an integral side lap extending sidewardly of at least some of the
marginal edges of the insulation, and the side lap being extendable
over the joint between adjacent panels to form a sealed joint
between adjacent panels on assembly.
43. The panel as claimed in claim 30 wherein the membrane comprises
a unitary sheet of membrane or film.
44. The panel as claimed in claim 30 wherein the membrane is
substantially planar.
45. The panel as claimed in claim 30 wherein the membrane is of
substantially uniform structure and thickness.
46. The panel as claimed in claim 30 wherein the membrane is of a
flexible plastics material.
47. The panel as claimed in claim 30 wherein the membrane is
attached to the insulation body except at a fixing region at one or
more of the marginal edges.
48. The panel as claimed in claim 47 wherein the side lap of the
membrane is extended to cover the fixing region on assembly.
49. The panel as claimed in claim 42 wherein the side lap extends
for bonding to an adjacent panel on assembly.
50. The panel as claimed in claim 49 wherein the side lap is bonded
to an adjacent panel on assembly.
51. The panel as claimed in claim 30 wherein the body of insulation
comprises an insulation foam.
52. The panel as claimed in claim 51 wherein the insulation foam is
factory formed in situ between the inner liner and the outer
layer.
53. The panel as claimed in claim 30 wherein the inner liner is of
metal.
54. The panel as claimed in claim 30 wherein the liner is a
profiled liner.
55. The panel as claimed in claim 54 wherein the liner comprises
nestable partial profiles at the side marginal edges thereof.
56. The panel as claimed in claim 55 wherein the joint formations
are provided at the edge of the partial profiles.
57. The panel as claimed in claim 56 wherein the partial profiles
are free of insulating material prior to assembly.
Description
INTRODUCTION
[0001] The invention relates to a roof panel for forming a low
pitch or flat roof.
STATEMENTS OF INVENTION
[0002] According to the invention there is provided a roof panel
for forming a low pitch or a flat roof, the roof panel comprising:
[0003] an inner liner; [0004] an outer weatherproof membrane;
[0005] a body of insulating material between the inner liner and
the outer membrane;
[0006] wherein the inner liner comprises joint formations for
forming a nested side lap joint between adjacent panels.
[0007] In one embodiment the joint formations are adapted for
clinching.
[0008] In one case the joint formations comprise a first joint
formation on one edge of the liner and a second joint formation on
an opposite edge of the liner, the first liner formation of one
panel being adapted for interengaging and for clinching with a
second liner form of an adjacent panel.
[0009] The first liner formation may comprise a liner extension
which is shaped to define a recess. The second liner formation may
comprise a liner extension which is shaped to form a liner
projection for locating in the liner recess of an adjacent
panel.
[0010] The liner may comprise an inturned leg and a return leg
which define the liner recess therebetween.
[0011] The liner may comprise an inturned leg which defines the
liner projection. The liner projection may have a return lip to
reinforce the projection.
[0012] In one embodiment the panel comprises a fastener for
fastening the panel to a support such as a purlin. The fastener may
be a self-coring fastener.
[0013] In one embodiment the panel comprises a filler for location
in the nested side lap joint forming portions of the inner liner.
The filler may be of insulation material.
[0014] In one embodiment the membrane comprises an integral side
lap extending sidewardly of at least some of the marginal edges of
the insulation, and the side lap being extendable over the joint
between adjacent panels to form a sealed joint between adjacent
panels on assembly.
[0015] The membrane may comprise a unitary sheet of membrane or
film. The membrane may be substantially planar. The membrane may be
of substantially uniform structure and thickness.
[0016] In one case the membrane is of a flexible plastics material.
The membrane may be pre-attached to the insulation body except at a
fixing region at one or more of the marginal edges. The side lap of
the membrane may be extended to cover the fixing region on
assembly.
[0017] In one case the body of insulation comprises an insulation
foam. The insulation foam may be factory formed in situ between the
inner liner and the outer layer.
[0018] In one embodiment the inner liner is of metal. The liner may
be a profiled liner.
[0019] In one embodiment the liner comprises nestable partial
profiles at the side marginal edges thereof.
[0020] The joint formations may be provided at the edge of the
partial profiles.
[0021] In one embodiment the partial profiles are free of
insulating material prior to assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The invention will be more clearly understood from the
following description thereof given by way of example only, in
which:
[0023] FIG. 1 is a cross sectional view of a roof panel according
to the invention;
[0024] FIG. 2 is a cross sectional view of a joint between two
adjacent roof panels;
[0025] FIG. 3 is an enlarged cross sectional view of the joint
detail;
[0026] FIG. 4 is a cross sectional view of a liner joint detail;
and
[0027] FIG. 5 is a cross sectional view of a clinched linear
joint.
DETAILED DESCRIPTION
[0028] Referring to the drawings there is illustrated a roof panel
1 according to the invention for use in forming a low pitch or flat
roof.
[0029] The roof panel 1 comprises a profiled inner liner or decking
sheet 2, an outer waterproof membrane 3 and a body 4 of insulation
between the inner liner 2 and outer membrane 3.
[0030] The membrane liner sheet 3 has a backing such as a fleece or
scrim to aid adhesion of the membrane 3 to the foam body. The
membrane 3 may be of a suitable plastics material such as PVC, TPO
and the like. The plastics membrane 3 is provided with a suitable
backing such as a fleece or fabric.
[0031] The membrane 3 comprises a side lap 5 extending sidewardly
of at least some of the marginal edges of the body 4. The side lap
5 which does not have a fleece or fabric backing is extended over a
joint between adjacent panels to form a sealed joint between the
adjacent panels on assembly.
[0032] The membrane 3 is manufactured of a unitary sheet of
membrane or film. The side lap 5 is integral with the membrane 3
pre-bonded to the panel. The membrane 3 is of substantially uniform
structure and thickness throughout and is substantially planar.
[0033] The inner liner 2 which may be of painted galvanised steel
is formed with trapezoidal portions 9 for improved mechanical and
insulation performance.
[0034] The insulation may be of any suitable foam material such as
a polyurethane foam, a polyisocyanurate foam, or a phenolic
foam.
[0035] The inner liner 2 comprises joint formations a the side
marginal edges thereof for forming a nested side lap joint between
adjacent panels. The joint formations comprise a first joint
formation 20 at one edge of the liner 2 and a second joint
formation 21 on an opposite edge of the liner. The first and second
joint formations 20, 21 of adjacent panels are adapted to
interengage on assembly as illustrated in FIG. 4 and are clinched
together using a clinching tool 22 as illustrated in FIG. 5 to form
a clinched joint 25.
[0036] The first joint formation 20 comprises a liner extension
which is shaped to define a recess. There is an inturned liner leg
26 and a return leg 27 which define a liner recess
therebetween.
[0037] The second liner formation 21 comprises a liner extension
which is shaped to define a projection which is engagable in the
recess defined by the first liner extension 20. The liner
projection is defined by an inturned liner leg which has a return
lip 28 to reinforce the projection.
[0038] Partial formations, in this case partial trapezoidal
portions 7, 8 at the side marginal edges of the liner 2 extend
laterally of the liner 2 and are free of insulating foam material
when manufactured for nesting at the joint between adjacent panels.
The joint formations 20, 21 are provided at the free edges of the
partial trapezoidal portions 7, 8. On assembly, the partial
trapezoidal portions 7, 8 of adjacent panels are overlapped and
interengaged for enhanced structural strength. On assembly of
adjacent panels on site, the liner formations 20, 21 are
inter-engaged and clinched together. The clinched joint is then
covered with an insulating foam filler 30 to provide insulation at
the joint.
[0039] Self coring fasteners 35 are used to fix the panels to an
underlying support 36 such as a purlin or the like.
[0040] The membrane 3 is applied to the panel 1 at the site where
the panel is manufactured. The membrane is bonded to the panel such
that an integral membrane side lap 5 extends sidewardly of at least
some of the marginal edges of the panel. The membrane 3 may be
bonded to the panel except at one or more of the marginal edges.
The membrane 3 has a generally smooth finish on the weather (outer)
side. On the backing side of the membrane which is in contact with
the foam there may be a fleece backing to assist in ensuring a good
bond between the membrane 3 and the foam 4. The overlap portion 5
does not have a fleece backing.
[0041] The membrane has a side lap 5 to which the outer layer is
not bonded and this side lap may be un-fleeced (no fabric) in this
region or the adhesive may be covered with a release tape or the
like.
[0042] A composite panel is produced by laying down liquid foam
reactants onto the liner layer 2. The trapezoidal portions 7, 8 are
left free from foam. The liquid foam reactants may be poured onto
the inner liner 2 and the outer layer 3 applied over the liquid
foam reactants. The sandwich thus formed is heated in an oven and
the liquid foam reactants expand to fill the space between the
inner liner 2 and the outer membrane layer 3.
[0043] The panel thus formed is cut to a desired length.
[0044] In use, a roof is built up by laying a number of the panels
side by side on support purlins. The joints between adjacent panels
are sealed by extending the sidelaps 5 over the joints between
adjacent panels and by then applying the side or end laps which may
be heat sealed, hot air welded, solvent welded or adhesively bonded
to the membrane of an adjacent panel. The overlapping portion of a
side or end lap where provided is extended over the free fixing
region of the panel and may be similarly sealed to the outer
layer.
[0045] The panels are formed so that on assembly and
interengagement a generally flat face to enable the membrane cover
to be extended to completely cover the panel and joints between
adjacent panels on assembly.
[0046] In use, when the panels are overlapped on site primary
fixing is carried out using self coring fasteners which are applied
from above and core down through the foam 4 and fasten the liner 2
to the supporting structure 36 below. Side-lap clinching of the
nested joints is then performed, again from above. Finally, the
factory cut foam inserts 30 are applied and the membrane 5 lap
joint is welded.
[0047] The roof panels of the invention offer considerable
advantages both in terms of mechanical performance and thermal
efficiency.
[0048] As shown in the drawings the invention provides a low pitch
or flat roof system for the installation and assembly of a
waterproof sealed roof.
[0049] The invention is not limited to the embodiments hereinbefore
described which may be varied in detail.
* * * * *