EP0409513A1

EP0409513A1 - Roof/wall panel

Info

Publication number: EP0409513A1
Application number: EP90307723A
Authority: EP
Inventors: Robert Telfer Mcneil
Original assignee: PANELSPAN Ltd
Current assignee: PANELSPAN Ltd
Priority date: 1989-07-15
Filing date: 1990-07-13
Publication date: 1991-01-23
Also published as: GB8916262D0

Abstract

A roof or wall panel (1) is formed having a prelaminated plastics-to-metal outer layer (4). The panel (1) further comprises an inner layer (2) preferably made from metal, and a middle insulating layer (3) made from for example, extruded polystyrene foam. The panels (2) are substantially rectangular, and a pair of opposed longitudinal edges (5) of the outer layer (4) stand proud relative to the outer surface of the panel (1) that when the panels (1) are placed with these edges adjacent, the edges form a standing seam (6). A flexible plastics membrane (7) may subsequently be bonded across and along the length of the standing seam (6) and a prelaminated plastics-to-metal flashing (13) fixed across the seam (6) to finish it. A suitably shaped timber or plastic strip (9) may further be located within the standing seam (6) to provide structural support and for a thermal break or cold bridge insulation.

Description

The present invention relates to roof or wall panels, and in particular to panels employing a prelaminated plastics- to-metal layer.
Presently prelaminated plastics-to-metal sheeting is used in various roofing applications such as in providing backing angles or counter flashing. Further, metal sheet panels are often used in preference to conventional lead or copper roofs, such panels frequently being fabricated from aluminium based alloys. These panels are secured side by side in a waterproof joint, and are normally clinked together. In the case of metal sheeting, hidden cleat fixings are used to clip the sheets in place. A problem arises, however, in that a high degree of skill requires to be exercised by a tradesman in making the seams between these panels or sheets waterproof.
It is an object of this invention to obviate or mitigate the aforementioned disadvantages.
According to one aspect of the present invention there is provided a panel comprising an inner layer, a middle insulating layer and an outer prelaminated plastics-to- metal layer.
Preferably the inner layer and the middle insulating layer are adhered to one another using a suitable adhesive.
Preferably also, the middle insulating layer and the outer prelaminated plastics-to-metal layer are adhered to one another using a suitable adhesive.
Preferably also, the inner layer is fabricated from metal.
Preferably also, the middle insulating layer comprises extruded polystyrene foam.
Preferably also, the plastics material used in the prelaminated plastics-to-metal layer is PVC.
Preferably also, any edges of any panels which are exposed are finished using suitably shaped prelaminated plastics to metal edge pieces.
Preferably also, the panel is suitably retained in association with a structural steel timber or concrete member, e.g. a purlin by retaining means, e.g. self tapping screws.
Preferably the panel is rectangular and a pair of opposed edges of the outer layer are suitably contoured so as to be proud relative to the outer surface of the panel such that when two panels are placed with said edges adjacent, said edges form a standing seam.
Preferably the inner layer has longitudinal sides, the ends of which form a lip overlying said inner layer, and preferably also, the outer layer is secured to said lips.
Preferably also, a flexible plastics membrane strip is fixed over the standing seam to provide a water tight joint.
Preferably the flexible plastic strip is fixed by hot welding or by using a suitable adhesive.
Preferably also, the flexibile plastics strip is made from a plastics material compatible with that of the plastics-to-metal prelaminated layer.
Preferably also, a suitably shaped timber or plastics material is placed within the standing seam to provide structural support and/or a thermal break or cold bridge insulation.
Preferably also, one of the transverse ends of the panel is provided with a raised lip, the raised lip being such that when two panels are placed end to end the lowermost edge of the upper panel provided with a raised lip will overlap the uppermost edge of the lower panel having no lip.
Preferably also, a prelaminated plastics-to-metal flashing is provided to cover the standing seam the flashing providing both additional sealing means and also finishing the seam.
Preferably also the flashing is adhered to the standing seam using a suitable material, e.g. a bituminous mastic.
According to another aspect of the present invention there is provided a roof or wall formed from a plurality of panels as defined in the fourth paragraph herein, wherein adjacent panels have an outer prelaminated plastics-to-metal layer, and a flexible plastics membrane strip overlaps and is bonded to the longitudinal edges of adjacent panels to provide a water tight joint, the material of the membrane being compatible with that of the prelaminated plastics-to-metal layer.
Preferably the longitudinal edges of adjacent panels are suitably contoured to form a standing seam, the flexible plastics membrane strip being bonded across and along the length of the standing seam.
Preferably also, a prelaminated plastics-to-metal flashing is fixed across the standing seam to provide a decorative finish.
According to a further aspect of the invention there is provided a roof or wall structure formed from a plurality of panels, as defined in the eleventh proceeding paragraph, said panels being arranged with at least the proud edges of the outer layer of adjacent panels being adjacent to each other to form a standing seam, a weatherproof flexible plastics membrane strip overlapping the standing seam, said strip being bonded to the plastics of the laminated outer layer of the adjacent panels.
Preferably said structure includes a plurality of fixed rails spaced to receive at least one panel between adjacent pairs of rails wherey adjacent panels have a rail between them, the side walls of the panels being longer than the height of the rail so that space is provided above the rail for cold bridge insulation to be provided below the weatherproof strip.
Preferably a plastics-to-metal capping strip is located over the weatherproof strip
An embodiment of the present invention will now be described, by way of example only, with reference to the accompanying drawings, which are:

Fig. 1 a cross-sectional view of a transverse edge of two panels according to the invention, held in association with one another;
Fig. 2 a partial perspective view of the two panels of Fig. 1 showing the transverse edges and the standing seam.
Fig. 3 is a perspective view of a second embodiment;
Fig. 4 is a detail to an enlarged scale on the line 4-4 of Fig. 3; and
Fig. 5 is another detail to an enlarged scale on the line 5-5 of Fig. 3.

Referring now to the drawings, two roofing panels 1,1′ are shown. Each of these panels comprises a substrate metal layer 2,2′ fabricated from a suitable metal and approximately Imm to 3mm thick, an extruded polystyrene foam middle insulating layer 3,3′ approximately 5cm to 10cm thick, and prelaminated plastic-to-metal topmost layer 4,4′ approximately 1mm to 5mm thick, the plastic laminate being on the outer surface of the panel 1,1′.
The substrate metal layer 2,2′ and the insulating layer 3,3′, and also the insulating layer 3,3′ and the topmost prelaminated layer 4,4′, are adhered to one another using suitable conventional adhesives. Further, each panel 1,1′ is approximately 0.6m wide and 2m long.
The longitudinal edges 5,5′ of the panels 1,1′ are shaped in such a way that when two panels are placed with one of the longitudinal edges 5,5′ of each of the panels 1,1′ adjacent one another then the two adjacent edges 5,5′ form a standing seam 6, the standing seam 6 running the whole length for which the panels 1,1′are adjacent. A compatible flexible plastic membrane strip 7 is provided, the strip 7 being fixed by hot welding over, and along the length of, the standing seam 6, to provide a water tight joint.
Once the standing seam 6 has been substantially sealed to moisture using the flexible PVC membrane 7, a bitumious mastic 16, e.g. Pib500 produced by Expandite, may be used to adhere a PVC metal laminate flashing 13 to the PVC membrane strip 7 so covering the standing seam 6 and finishing the join between the two panels 1,1′. The bituminous bedding mastic 16 may be supplied in tape form.
The PVC metal laminate flashing 13 may be supplied in suitable lengths, and placed over the standing seam 6 such that on an inclined roof the lower end of a length of flashing will overlap the upper end of a lower adjacent flashing thus reducing the likelihood of water ingression into the standing seam 6.
For most applications the mastic 16 will provide a bond having a sufficient grab factor between the strip 7 and the flashing 13. However, in particular windy locations additional fixing means may be required.
Metal plates 14 may therefore be placed at suitable centres across the standing seam 6 prior to the flashing 13 being placed over the standing seam 6, and a bulb-bite rivet 15 riveted through the flashing 13, plate 14 and standing seam 6 to provide means of strengthening the fixing between the flashing 13 and the strip 7.
Each panel 1,1′ may also be fabricated such that one of the transverse edges 8,8′, i.e. the transverse edge to be placed lowermost on an inclined roof, provides a raised lip (not shown) approximately 1cm to 10cm long such that when. panels are placed on a roof the join between the lowermost edge of one panel and the uppermost edge of the adjacent panel will be covered by the lip thus reducing the likelihood of water leaking through transverse joints between adjacent panels.
Further, a suitably shaped timber insert or thermal break 9 may be inserted within the standing seam 6, the break 9 further providing means for strengthening structural support at or near the standing seam 6.
It can be envisaged that prior to the application of the membrane 7, individual panels may be suitably retained in association with structural timber or concrete members 12 such as purlins by self tapping screws 10,10′ placed at suitable distances along the length of the longitudinal edges of the panels 1,1′, the self tapping screws 10,10′ extending from the suitably contoured longitudinal edge 5,5′ through the break 9 and the panel 1,1′ to the structural member 12.
The edges, both longitudinal 5,5′ and transverse, of the panels 1,1′ may be provided with suitable metal edge supports 11,11′ the edge supports 11,11′ providing means for sealing the inside of each panel 1,1′. It can be seen that metal edge supports 11,11′ are therefore of particular importance at edges which would remain exposed, e.g. near the eaves of the roof or near a gable end.
The insulating layer 2,2′ will further be tailored to meet the requirements of the statutory U value, dependent upon whether the panels are to be used in a commercial or a domestic application.
Referring now to the second embodiment and to Figs. 3 to 5. Each panel 20 comprises a tray which slidably locates between two pre-fixed rails 2I of inverted T shape. In this embodiment, in which the panels are roofing panels, the rails 21 are secured to purlins 22 of a roof stucture, e.g. by screws. The rails 21 are formed of two L-shaped steel angles welded back-to-back.
Each panel 20 has a substrate layer or base 23 of galvanised metal which bends into two longitudinal sides 24; these sides extend above the height of the rails 21 and are bent over at their upper ends to form lips 25 which overlie the base 23.
A top most layer 26 of prelaminated plastics-to-metal sheeting is located over the tray and secured to the tray lips 25 by pop rivets 27 at intervals along the length of the tray.
The top layer 26 is contoured so that the longitudinal ends thereof are raised relative to the surface of the top layer 26; thus when two panels 20 are placed side by side a standing seam 28 is formed, as illustrated in Fig. 4.
At one end of the panel 20, the upper end in use, the plastics laminate which is bonded to the metal sheeting by adhesive is turned back on itself to form a welt 29 as best shown in Fig. 5.
Within the space between the base 23, the sides 24, and the top layer 26 foam insulation 30 is provided. The insulation may be cut from a block and fitted during assembly of the panel 20, or it may be injected into the space through a rivet hole 31 in a side wall 24, which hole 31 is subsequently used when securing the tray in place between two rails 21 via pre-drilled holes 32 in the rails 21.
As illustrated in Fig. 4, when two panels 20 are in position there is a space above the rail 2I and between the upper ends of the tray sides 24. That space is filled by a caulking medium 33, e.e. a bituminous based material such as polyisobutalane, to form a cold-bridge insulation, and a thin strip 34 of material such as neoprene is laid over the centre of the standing seam 28 to secure the caulking material 33. A broader strip 35 of weatherproofing material is then laid over the upper face of the standing seam 28 and heat welded or otherwise bonded to the edges of the adjacent panels 20. The material of the weatherproofing strip is compatable with the plastics membrane of the outer layer 26 of the panel, and may be the same material, e.g. PVC.
Once the weatherproofing strip 35 has been laid, a contoured capping cover strip 36 of plastics-to-metal sheeting is secured over the standing seam 28 by cleats, not shown, the capping 36 having sides 37 which extend along the sides of the standing seam 28. The capping 36 may alternatively be secured by adhesive or other means.
In the embodiment disclosed herein, the panels 20 are 2m in length so several panels may be mounted between each pair of rails 21, the panels 20 being placed end to end.
A galvanised inverted T shaped transverse rail or trimmer 40 is laid across the gap between the two rails 21, with its ends located on horizontal flanges 41 of the rails 21, and ends of the adjacent panels 20 locate on the horizontal flanges 42 of the trimmer 40. The plastics laminate 44 on one of the panels 20, in use the upper panel, extends beyond the lower end of the panel to provide an overhang which is laid over the upper end of the lower panel and secured thereto, e.g. by mastic 45 as shown in Fig. 5.
It is to be understood that the longer or shorter edges of the panels may constitute the longitudinal edges 24, the rails being suitably spaced accordingly.
The rows of panels 20 between adjacent pairs of rails 21 are 'staggered' so that the transverse joints are located in different positions.
The underside of each panel 20 may be finished, e.g. with stove paint enamel to form a decorative surface.
Whilst the panel 20 has been described as a roofing panel, it is to be understood that the panel may be applied as a wall or partition or as a facia.
The embodiments of the invention disclosed herein provides a particularly simple and easily constructed solution to long standing problems experienced within this art. It will, however, be appreciated that other modifications may be made within the scope of the invention.

Claims

1. A roof or wall panel (1), characterised in that it comprises an inner layer (2), a middle insulating layer (3), and an outer prelaminated plastics-to-metal layer (4).

2. A roof or wall panel (1) according to claim 1, characterised in that it is substantially rectangular. and a pair of opposed longitudinal edges (5) of the outer layer are suitably contoured so as to be proud relative to the outer surface of the panel (1)such that when the panels (1) are placed with said edges (5) adjacent said edges (5)form a standing seam (16).

3. A roof or wall panel according to claim 1 or 2, characterised in that the inner layer (2) has longitudinal sides, the ends of which form a lip overlying said inner layer (2), the longitudinal edges (5) of the outer layer (4) being secured to said lips.

4. A roof or wall panel (1) according to claims 1 to 3, characterised in that the panel (1) is suitably retained in association with a structural member (12) by retaining means (10).

5. A roof or wall panel (1) according to claims 1 to 4, characterised in that one of the transverse ends of the panel (1) is provided with a raised lip, the raised lip being such that when two panels (1) are placed end-to-end the lowermost edge of the upper panel provided with the raised lip overlaps the uppermost edge of the lower panel having no lip.

6. A roof or wall formed from a plurality of panels (20) as claimed in claims 1 to 5, characterised in that adjacent panels (20) have an outer prelaminated plastics-to-metal layer (26), and a flexible plastics membrane strip (34) overlaps and is bonded to the longitudinal edges (24) of adjacent panels (20) to provide a substantially water tight joint, the material of the membrane (34) being compatible with that of the prelaminated plastics-to-metal layer (26).

7. A roof or wall according to claim 6, characterised in that the longitudinal edges (24) of adjacent panels (20) are suitably contoured to form a standing seam (28), the flexible plastics membrane strip (34) being bonded across and along the length of the standing seam (28).

8. A roof or wall according to claim 7, characterised in that a prelaminated plastics-to-metal flashing (36) is forced across the standing seam (28).

9. A roof or wall according to claims 7 or 8, characterised in that a suitably shaped timber or plastics material (9) placed within the standing seam (28) provide structural support and for a thermal break or cold bridge insulation.

10. A roof or wall as claimed in claim 9, characterised in that the roof or wall includes a plurality of fixed rails (21) spaced to receive at least one panel (20) between adjacent pairs of rails (21) whereby adjacent panels (20) have a rail (21) between them, the side walls (24) of the panels (20) being longer than the height of the rail (21) so that space is provided above the rail (21) for cold bridge insulation to be provided below the membrane strip (34).