CA2777637C - A roof panel - Google Patents

A roof panel Download PDF

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Publication number
CA2777637C
CA2777637C CA2777637A CA2777637A CA2777637C CA 2777637 C CA2777637 C CA 2777637C CA 2777637 A CA2777637 A CA 2777637A CA 2777637 A CA2777637 A CA 2777637A CA 2777637 C CA2777637 C CA 2777637C
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CA
Canada
Prior art keywords
liner
panel
joint
membrane
formation
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
CA2777637A
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French (fr)
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CA2777637A1 (en
Inventor
Donal Curtin
Peter Simko
Donal Mccullagh
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kingspan Holdings IRL Ltd
Original Assignee
Kingspan Holdings IRL Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kingspan Holdings IRL Ltd filed Critical Kingspan Holdings IRL Ltd
Publication of CA2777637A1 publication Critical patent/CA2777637A1/en
Application granted granted Critical
Publication of CA2777637C publication Critical patent/CA2777637C/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D3/00Roof covering by making use of flat or curved slabs or stiff sheets
    • E04D3/35Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation
    • E04D3/351Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation at least one of the layers being composed of insulating material, e.g. fibre or foam material
    • E04D3/352Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation at least one of the layers being composed of insulating material, e.g. fibre or foam material at least one insulating layer being located between non-insulating layers, e.g. double skin slabs or sheets
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D3/00Roof covering by making use of flat or curved slabs or stiff sheets
    • E04D3/35Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation
    • E04D3/358Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation with at least one of the layers being offset with respect to another layer

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Roof Covering Using Slabs Or Stiff Sheets (AREA)
  • Laminated Bodies (AREA)

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.

Description

"A ROOF PANEL"
Introduction The invention relates to a roof panel for forming a low pitch or flat roof.
Statements of Invention According to the invention there is provided 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.
In one embodiment the joint formations are adapted for clinching.
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.
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.
The liner may comprise an inturned leg and a return leg which define the liner recess therebetween.
- 2 -The liner may comprise an intumed leg which defines the liner projection. The liner projection may have a return lip to reinforce the projection.
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.
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.
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.
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.
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.
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.
In one embodiment the inner liner is of metal. The liner may be a profiled liner.
In one embodiment the liner comprises nestable partial profiles at the side marginal edges thereof.
The joint formations may be provided at the edge of the partial profiles.
- 3 -In one embodiment the partial profiles are free of insulating material prior to assembly.
In a broad aspect, moreover, the present invention provides 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 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 inter-engaging and for clinching with a second liner from of an adjacent panel; and 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 a joint between adjacent panels to form a sealed joint between adjacent panels on assembly.
Brief Description of the Drawings The invention will be more clearly understood from the following description thereof given by way of example only, in which:-Fig. 1 is a cross sectional view of a roof panel according to the invention;
Fig. 2 is a cross sectional view of a joint between two adjacent roof panels;
Fig. 3 is an enlarged cross sectional view of the joint detail;
Fig. 4 is a cross sectional view of a liner joint detail; and Fig. 5 is a cross sectional view of a clinched linear joint.

=

- 3a -Detailed Description 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.
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.
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.
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
- 4 -backing is extended over a joint between adjacent panels to form a sealed joint between the adjacent panels on assembly.
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.
The inner liner 2 which may be of painted galvanised steel is formed with trapezoidal portions 9 for improved mechanical and insulation performance.
The insulation may be of any suitable foam material such as a polyurethane foam, a polyisocyanurate foam, or a phenolic foam.
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.
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.
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.
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,
-5-21 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.
Self coring fasteners 35 are used to fix the panels to an underlying support 36 such as a purlin or the like.
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.
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.
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.
The panel thus formed is cut to a desired length.
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
- 6 -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.
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.
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.
The roof panels of the invention offer considerable advantages both in terms of mechanical performance and thermal efficiency.
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.
The invention is not limited to the embodiments hereinbefore described which may be varied in detail.

Claims (26)

- 7 -
1. 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 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 inter-engaging and for clinching with a second liner from of an adjacent panel; and 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 a joint between adjacent panels to form a sealed joint between adjacent panels on assembly.
2. The panel as claimed in claim 1 wherein the first liner formation comprises a liner extension which is shaped to define a recess.
3. The panel as claimed in claim 2 wherein the liner comprises an inturned leg and a return leg which define the liner recess therebetween.
4. The panel as claimed in any one of claims 1 to 3 wherein the second joint formation comprises a liner extension which is shaped to form a liner projection for locating in the liner recess of an adjacent panel.
5. The panel as claimed in claim 4 wherein the liner comprises an inturned leg which defines the liner projection.
6. The panel as claimed in claim 5 wherein the liner projection has a return lip to reinforce the projection.
7. The panel as claimed in any one of claims 1 to 6 comprising a fastener for fastening the panel to a support.
8. The panel as claimed in claim 7 wherein the fastener is for fastening the panel support to a purlin.
9. The panel as claimed in claim 7 or 8 wherein the fastener is a self-coring fastener.
10. The panel as claimed in any one of claims 1 to 9 comprising a filler for location in the nested side lap joint forming portions of the inner liner.
11. The panel as claimed in claim 10 wherein the filler is of insulation material.
12. The panel as claimed in any one of claims 1 to 11 wherein the membrane comprises a unitary sheet of membrane or film.
13. The panel as claimed in any one of claims 1 to 12 wherein the membrane is planar.
14. The panel as claimed in any one of claims 1 to 13 wherein the membrane is of uniform structure and thickness.
15. The panel as claimed in any one of claims 1 to 14 wherein the membrane is of a flexible plastics material.
16. The panel as claimed in any one of claims 1 to 15 wherein the membrane is attached to the insulation body except at a fixing region at one or more of the marginal edges.
17. The panel as claimed in claim 16 wherein the side lap of the membrane is extended to cover the fixing region on assembly.
18. The panel as claimed in any one of claims 1 to 17 wherein the side lap extends for bonding to an adjacent panel on assembly.
19. The panel as claimed in claim 18 wherein the side lap is bonded to an adjacent panel on assembly.
20. The panel as claimed in any one of claims 1 to 19 wherein the body of insulation comprises an insulation foam.
21. The panel as claimed in claim 20 wherein the insulation foam is factory formed in situ between the inner liner and the outer layer.
22. The panel as claimed in any one of claims 1 to 21 wherein the inner liner is of a metal material.
23. The panel as claimed in any one of claims 1 to 22 wherein the liner is a profiled liner.
24. The panel as claimed in claim 23 wherein the liner comprises nestable partial profiles at the side marginal edges thereof.
25. The panel as claimed in claim 24 wherein the joint formations are provided at edges of the partial profiles.
26. The panel as claimed in claim 25 wherein the partial profiles are free of insulating material prior to assembly.
CA2777637A 2009-10-16 2010-10-18 A roof panel Active CA2777637C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US27265809P 2009-10-16 2009-10-16
US61/272,658 2009-10-16
PCT/IE2010/000060 WO2011045779A1 (en) 2009-10-16 2010-10-18 A roof panel

Publications (2)

Publication Number Publication Date
CA2777637A1 CA2777637A1 (en) 2011-04-21
CA2777637C true CA2777637C (en) 2018-01-16

Family

ID=43242887

Family Applications (1)

Application Number Title Priority Date Filing Date
CA2777637A Active CA2777637C (en) 2009-10-16 2010-10-18 A roof panel

Country Status (3)

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US (1) US20120227343A1 (en)
CA (1) CA2777637C (en)
WO (1) WO2011045779A1 (en)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SG148063A1 (en) * 2007-05-18 2008-12-31 James Lim Jee Keng Composite cement panel
US20190010702A1 (en) * 2017-07-05 2019-01-10 Robert Lloyd Metal laminate base sheet for use with masonry structure
WO2021108491A1 (en) 2019-11-26 2021-06-03 Building Materials Investment Corporation Roofing panels with water shedding features
CA3160250A1 (en) 2021-05-25 2022-11-25 Bmic Llc Panelized roofing system

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE7230778U (en) * 1974-01-10 Hoesch Werke Ag Composite element, in particular roof element
DE2016639A1 (en) * 1970-04-08 1971-11-18 Dlw Ag, 7120 Bietigheim Component
FR2142252A5 (en) * 1971-06-18 1973-01-26 Strati France
FR2509223A1 (en) * 1981-07-09 1983-01-14 Joris Jozef Roof and wall sandwich panel - formed by casting foam mixture on outer layer and pressing on metal profile

Also Published As

Publication number Publication date
WO2011045779A1 (en) 2011-04-21
US20120227343A1 (en) 2012-09-13
CA2777637A1 (en) 2011-04-21

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Effective date: 20151016