GB2245613A

GB2245613A - Roofing or cladding panel

Info

Publication number: GB2245613A
Application number: GB9014336A
Authority: GB
Inventors: Gordon William John Taylor
Original assignee: Individual
Current assignee: Individual
Priority date: 1990-06-27
Filing date: 1990-06-27
Publication date: 1992-01-08
Also published as: GB9014336D0

Abstract

A roofing or cladding panel (1) preferably having its outer exposed face (2) ribbed or otherwise shaped (3) to simulate a plurality of individual tiles or shingles; the panel (1) being formed such as by injection moulding from a rigid setting foamed plastics material such as a foamed polyurethane or foamed polystyrene to have a cellular structure within a smooth denser tough outer skin. The panel (1) is generally rectangular in face view and wedge shaped in end and transverse views; and has opposed hooked longitudinal upper and lower edge parts (4), (5) for interlocking engagement with opposite edge parts (5), (4) of similar panels (1) located in tiered relationship over a support structure (9). The panels (1) being securable in position by concealed fixing means (10) which also preferably define strengthening battens for the completed roof or cladding structure. <IMAGE>

Description

IMPROVEMENTS IN AND RELATING TO ROOFING AND CLADDING PANELS This invention relates to roofing and cladding panels, and more particularly relates to panels which are intended for securement to and cover over inclined or upright support structures of buildings eg roofs or walls of buildings,for external weather proofing.

An object of the present invention is to provide an improved construction of roofing or cladding panel with interlocking edge formations and manufactured of materials providing for economy in manufacture,ease of fixing and thermal insulation qualities.

Other and more particular objects and advantages of the invention will become apparent from the ensuing description.

According to a first aspect of this invention, there is provided a roofing or cladding panel moulded from a foamed plastics substantially rigid setting and water impervious material, said panel being of substantially rectangular form in face view and arranged in use to be positioned in an inclined or upright manner to have a longitudinal upper edge flanged part and a parallel longitudinal lower edge flanged part; said upper edge flanged part being shaped to project outwardly relative to and downwardly over said face and said lower edge flanged part being shaped to project inwardly relative to and upwardly under the panel to define upper and lower complementary channel formations enabling interlocking engagement of the upper and lower flanged edge parts of similar panels located in tiered relationship.

According to a second aspect of this invention, there is provided a roofing or cladding means comprising a plurality of the panels according to the preceding paragraph and fixing means therefor for securement of the panels to a support structure and in their interlocked tiered relationship; said fixing means comprising a plurality of fixing members fabricated from a thin strong and substantially rigid metal or plastics material and being shaped to have a flat base part arranged to be fastened to the support structure, and integral outwardly projecting and returned flange parts arranged to. locate as a close fit over the upper longitudinal edge flanged part of a lower panel to be fixed and within the lower longitudinal edge flanged part of a subsquently fitted next tiered similar panel.

For a building roofing structure, the panels define tiles and may be elongate in form and provided with decorative ribbed or shaped outer face formations simulating a plurality of individual tiles or singles.

The invention further includes the methods of fixing the roofing or cladding panels or tiles on abuilding structure and as hereinafter described.

Some preferred aspects of the invention will now be described more particularly described and illustrated by way of example and with reference to the accompanying drawings, in which: FIGURE 1 is a face view of one preferred form of panel in accordance with the invention, FIGURE 2 is a view in the direction of arrows II-II of figure 1 of the lower longitudinal edge of the panel, FIGURE 3 is an end view in the direction of arrows III-III of figure 1 of the panel, FIGURE 4 is an enlarged fragmentary sectional view in the direction of arrows IV-IV of figure 1 showing a preferred edge sealing arrangement, and FIGURE 5 is a diagramatic sectional view showing a number of the panels fixed in tier relationship as roofing tiles on a roof structure.

It is common these days to simulate the older concrete and clay roofing tiles by fabricating tile panels from sheet metal in providing relatively lightweight and readily fixed roofing structures, and also commonly known to provide sheet plastics cladding materials; and a more recent innovation is the provision of cavity wall construction plastics weather boarding and like panels providing for some thermal insulation and generally dispensing with the need for more painting.

The present invention provides further improved thermal insulation for building structures and is particularly useful for roof structures in providing a decorative tiled thermally insulated roof reducing the need for added ceiling insulation, where there is normally the greatest heat loss.

The illustrated forms of the invention particularly relate, by way of example, to a roofing tile system and each panel (generally indicated by the arrow 1) is moulded from a rigid setting foamed plastics material such as a foamed Polyurethane or foamed Polystyrene material to have good thermal insulating qualities by virtue of the trapped air cellular form, and also providing a very lightweight panel which is readily handled by a cladding fixer.

Whilst the panels 1 can be of single tile form for a roof, it is preferable that they are elongate in form and have the outer faces 2 provided with spaced ribs or like configurations 3 so that each elongate panel 1 simulates a series of similar fixed tiles. The plastics material utilised in a construction of each tile panel is preferably pre-coloured to the desired roofing colour and the preferred high pressure injection moulding process employed ensures that at least the outer face 2 and edge parts 4,5,6, & 7 of each panel are smooth and relatively dense so as to ensure that the panels 1 are water impervious and weather resistant.Whilst the selected colours can be employed in the plastics materials prior to forming into the panels 1 it is envisaged that the same colour extending fully through each panel is not an essential factor and a neutral or white common coloured plastics can be employed for all materials, and individual batches of formed tile panels 1 coloured externally at least as required by a spray coating with a compatible plastics coating of the desired colour and which will permanently bond to the plastics material employed in the panel formation.

Each panel 1 is of elongate rectangular form in face view and preferably of wedge-shaped form in end and transverse views so as to have fairly substantial thickness towards the lower edge parts of the tile panels 1; and so that the lower faces 8 or undersides of such panels 1 can lie flat on the upper surfaces of rafters or bearers 9 of the roofing structure for added strength and stability.

As shown in the drawings, in the moulding of the plastics tile panels 1 the upper longitudinal edge parts 4 project upwardly and have short longitudinal flange parts 4a extending downwardly over the face parts in spaced relationship therefrom to define an upper edge downwardly facing channel or rebate 4b and the lower edge part 5 of each tile panel 1 is of reduced thickness relative to the previously mentioned thicker lower parts la and is shaped to extend downwardly and have a short longitudinal flange part 5a extending inwardly under such reduced thickness panel part 5 to define an opposed upwardly directed lower channel or rebate 5b on the underside of the panel 1; the shape and dimensions of the upper and lower longitudinal flanged edge parts 4 and 5 being such that similar panels 1 located in tiered relationship can be interlocked with their upper flanged edges 4a located in the lower channel or rebate 5b of the next panels 1 and the lower flange edge parts 5a located in the upper channels or rebates 4b of the lower tile panels 1 and as a close fit. Where the panels 1 are provided with projecting ribs 3 on the upper face 2 to define the tile formations, such ribs 3 would be arranged to terminate short of the upper flanged edges 4a to allow engagement of the tiered panel edge portions as aforesaid.

Often, building roofing tiles and like panel structures require fixing by means of nailing through edge parts of the tiles; and this manner of fixing has distinct disadvantages in providing a potential leak area for the ingress of rain water and/or may lead to damage of the tiles when hammering some fixing nails. Accordingly, the present invention further includes a hidden fixing means whereby the tile panels 1 can be securely fixed in position without nails or like fasteners being passed through the panels 1 into the support rafters or bearers 9. Whilst it is envisaged that a plurality of similar short fastening clips can be employed, it is preferable that elongate fixing members 10, which also act as strengthening battens, are provided and employed in fixing the tile panels 1 on the support structure.The fixing members or battens 10 can conveniently be fabricated from relatively thin strong sheet or strip metal by any suitable folding or shaping meahs; but it is envisaged that a strong rigid setting plastics material can be employed if preferred and the battens may be formed such as by heating and folding pre-formed sheet or strip plastics material, or formed such as by a continuous extrusion process.Each batten fixing member 10 has a flat base part 1 ova which is arranged to be secured in the desired position longitudinally and horizontally over the roof structure (and such as by nails or like fasteners directly to the inclined rafters and bearers 9 of such structure; and the batten fixing members 10 have upstanding wall parts 1Ob extending from the base parts 10a and merging into longitudinal downwardly directed flange parts 10c having inturned or hooked lower edges lOd and shaped so as to locate over the upper flange edge parts 4 of the respective tile panels and hook into the upper channels or rebates 4b thereof, and be sandwiched between the upper longitudinal edge 4a of the lower tile panel and the interconnected lower edge part 5a of the next upper tile panel 1.The method of fixing will generally involve fixing first of a plurality of the batten fixing members 10 in the desired horizontal spaced relationship as prescribed by the tile or panel widths, and fixing of the panels 1 in their tiered and series relationship over the roof structure; working from the outer lower side of the roof structure by urging the upper flanged edge parts 4 of the lowermost ones of tile panels 1 into spring fit engagement with the first batten fixing member 10; locating the next run of tile panels 1 similarly into position, but simultaneously interlocking the lower flanged edge portions 5a with the upper edge flanged portions 4a of the first fixed tier or run of tile panels 1 whilst spring fit engaging the upper flanged edge part 4a of the second run of tile panels 1 into the next batten fixing member 10, and so forth.A special outer end fixing member 10 can be employed for the first run of tile panels 1 and be of substantially Z formation,with the lower base part 10'a extending upwardly of the rafters or bearers 9 at the outermost edges thereof so that the upper flanged part 10'c with which the lower flanged edge part 5a of the lowermost and outermost run of tile panels 1 is to be engaged) will extend over the normally provided fascia board 11 and gutter inner wall 12a to allow the desired overlap of the lower run of tile panels 1 with the gutter 12.It is alternatively envisaged that all batten fixing members 10 can be similar to the outermost batten fixing member 10' referred to, if preferred; and such alternative batten fixing members 10' would allow for their location over first laid tile panels 1, and nail fixing to the support structure before laying of the next upper run of tile panels.1.

The tile panels 1 are arranged for end (6,7) butting relationship in each tier or horizontal run,and weather -proofing at the abutting joints 15 is arranged to be effected by the provision at one end of an open water channel or recess 13 inset from one end of the upper face of each tile panel 1 and extending between the upper and lower edge parts 4 and 4; and the provision at the opposite end of a joint overlap part 3a, which can be similar in external appearance to the ribs 3 so as to give an un-interrupted tile run appearance, with a depending smaller rib or bead 14 extending between the upper and lower edge parts 4 and 5 and inset medially between the free edge of the overlap part 3a and adjacent end wall 7 of the panel 1 (in spaced relationship therefrom) so as to be locatable with the water channel 13 of a next similar panel in the run.The overlap part 3a concealing the joint 15 between the adjacent panels 1 of the run.

Thus, it will be seen that a roof cladding system involving simulated tile panels can be readily fixed rapidly and with a minimum of effort, and in a manner providing for hidden fixing without nails or other fastening members being passed through the tiles; and the tile panel structure employed will provide a sound weatherproof and thermally insulated roof having a pleasing appearance. It will be seen that whilst a roofing tile structure has been particularly described and illustrated, upright wall cladding panels can be similarly provided and fixed as for cladding and simulating weatherboarding singles or the like.

Preferred aspects of the invention have been described and illustrated by way of example, but it will be appreciated that other variations of and modifications to the invention can take place without departing from the scope of the appended claims.

Claims

WHAT I CLAIM IS:

1. A roofing or cladding panel moulded from a foamed plastics substantially rigid setting and water impervious material, said panel being of substantially rectangular form in face view and arranged in use to be positioned in an inclined or upright manner to have a longitudinal upper edge flanged part and a parallel longitudinal lower edge flanged part; said upper edge flanged part being shaped to project outwardly relative to and downwardly over said face and said lower edge flanged part being shaped to project inwardly relative to and upwardly under the panel to define upper and lower complementary channel formations enabling interlocking engagement of the upper and lower flanged edge parts of similar panels located in tiered relationship.

2. A roofing or cladding panel as claimed in claim 1, wherein said panel is of elongate form and has outer face decorative ribbed or shaped formations simulating a plurality of individual tiles or shingles.

3. A roofing or cladding panel as claimed in claim 1 or claim 2, wherein said panel is formed by high pressure injection moulding from a foamed polyurethane or foamed polystyrene material to have a cellular inner form with a relatively dense smooth and tough outer skin.

4. A roofing or cladding panel as claimed in any one of the preceding claims, wherein said panel is coated after moulding with a compatible plastics coating of a desired colour and a material which will permanently bond to the plastics material employed in the panel formation.

5. A roofing or cladding panel as claimed in any one of the preceding claims, wherein said panel is of substantially wedge-shaped form in end and transverse views so as to have fairly substantial thickness towards the lower longitudinal edge and decreasing in thickness towards the upper longitudinal edge part; said lower longitudinal edge part being of reduced thickness and being shaped and spaced relative to the lower or inner face of the wedge shaped part so as to be able to accommodate and interlock with the upper longitudinal edge part of a next similar panel located in tiered relationship and with said lower or inner faces of the wedge shaped parts of the similar panels aligned and arranged to lie flat on a support surface for the similar panels.

6. A roofing or cladding panel as claimed in any one of the preceding claims, wherein said panel is arranged for end butting relationship with a next similar panel in a tier or horizontal run of similar panels, and said panel has one end part formed with an open water channel or recess inset from that end of the panel and on the upper or outer face thereof to extend between the upper and lower edge parts of the panel; the opposite end of the panel being formed with a joint overlap part projecting laterally therefrom and having a depending small rib or bead extending between the upper and lower edge parts of the panel and being inset medially between the free edge of the overlap part and adjacent end wall of the panel (in spaced relationship therefrom) so as to be locatable in the end water channel of a next similar panel in a run of the similar panels, with the overlap part concealing the joint between adjacent panels of the run.

7. A roofing or cladding panel arranged and constructed substantially as hereinbefore described with reference to the accompanying drawings.

8. A roofing or cladding means comprising a plurality of the panels according to any one of the preceding claims and fixing means therefor for the securement of the panels to a support structure and in their interlocked tiered relationship; said fixing means comprising a plurality of fixing members fabricated from a thin strong and subtantially rigid metal or plastics material and being shaped to have a flat base part arranged to be fastened to the support structure, and integral outwardly projecting and returned flange parts arranged to locate as a close fit over the upper longitudinal edge flanged part of a lower panel to be fixed and within the lower longitudinal edge flanged part of a subsequently fitted next tiered similar panel.

9. A roofing or cladding means as claimed in claim 8, wherein said fixing members are elongate fixing members defining strengthening battens for interlocked upper and lower longitudinal edge parts of the panels.

10. A roofing or cladding means comprising a plurality of the panels according to any one of claims 1 to 7 inclusive mounted, interlocked and secured with fixing members substantially as hereinbefore described with reference to the accompanying drawings.