GB2347696A

GB2347696A - Gutter formed from insulated panels

Info

Publication number: GB2347696A
Application number: GB0003821A
Authority: GB
Inventors: Eoin T Mccarthy; James Carolan; Martin Crosbie
Original assignee: Kingspan Research and Developments Ltd
Current assignee: Kingspan Research and Developments Ltd
Priority date: 1999-02-19
Filing date: 2000-02-21
Publication date: 2000-09-13
Anticipated expiration: 2020-02-21
Also published as: IE20000136A1; GB2347696B; GB0003821D0

Abstract

A composite panel (1B) of an insulated roof guttering system has an outer skin (5), an inner skin (6) and a core (7) of insulation sandwiched between the skins (5,6). The inner skin (6), which can be made of metal is coated with a waterproof membrane (8) that is bonded to the inner skin (6), except for a membrane sealing portion (8A) at one end. On assembly the sealing portion (8A) is overlapped onto the membrane (8) of an opposite end of an adjacent panel (1A) and heat sealed (fig 4). End portions of outer skins (5) and inner skins (6) of adjacent panels are also overlapped on assembly.

Description

"A SYSTEM2S Introduction The invention relates to a gutter system, especially a roof gutter system. The invention also relates to a composite gutter panel.

Various types of insulated roof gutter systems are known. There are however a number of problems with such conventional systems. Some systems are difficult and/or complex to manufacture, assemble, and/or fit on site. Other systems are not effectively and efficiently sealed leading to leakage problems and/or inferior insulation properties.

This invention is directe towards providing an improved gutter system and especially a composite gutter panel which will overcome at least some of these difficulties.

Statement of Invention According to the invention there is provided a gutter system comprising : at least two composite gutter panels; each composite panel comprising an outer skin, an inner skin and a core of insulation material therebetween; the inner skin having a waterproof membrane ; adjacent panels being over-lapped at a joint therebetween ; and membrane se means for sealing the joint between adjacent panels, on assembly.

In one embodiment of the invention the membrane sealing means comprises an extension of the waterproof membrane of the inner sldn. Preferably the membrane sealing means comprises a joint portion of the waterproof membrane of the inner skin. The joint portion is unbonded to overlap, on assembly, with the waterproof membrane of an adjacent panel.

In another embodiment of the invention the membrane sealing means is heat sealable at the joint.

Ideally the inner skin comprises a metal skin with a membrane bonded thereto.

In a preferred embodiment of the invention each panel has a lateral extension of the inner skin at one end for overlapping with the inner skin of an adjacent panel, on assembly.

In another preferred embodiment of the invention each panel has a lateral extension of the outer skin at one end for overlapping with the insulation core of an adjacent panel, on assembly.

Preferably the inner skins of adjacent panels inter-engage, on assembly, to form a jogglejoint.

According to another aspect of the invention, there is provided a composite gutter panel comprising an outer skin, an inner side, and a core of insulation material therebetween, the inner skin having a waterproof membrane, the panel having overlapping means for overlapping, on assembly, with another composite gutter panel, and membrane sealing means for sealing the joint between adjacent panels, on assembly.

In one embodiment of the invention the membrane sealing means comprises an extension of the waterproof membrane of the inner skin. Preferably the membrane sealing means comprises a joint portion of the waterproof membrane of the inner skin. The joint portion is unbonded to overlap, on assembly, with the waterproof membrane of an adjacent panel.

Ideally the inner skin comprises a metal skin with a membrane bonded thereto.

In a preferred embodiment of the invention the composite gutter panel has a lateral extension of the inner skin at one end for overlapping with the inner slan of an adjacent panel, on assembly.

In another preferred embodiment of te invention the composite gutter panel has a lateral extension of the outer skin at one end for overlapping with the insulation core of an adjacent panel, on assembly.

Preferably the outer skin indures joggle joint forming means which inter-engage on assembly to form a joggle joint.

Brief D ioi2 win The invention will be more dearly understood from the following description thereof, given by way of example only, with reference to me accompanying drawings, in which : Fig. 1 is a longitudinal cross sectional view of a composite roof panel according to the invention ; Fig. 2 is a cross sectional view of a joint between adjacent panels of Fig. 1 ; Fig. 3 is a perspective, partially cut-away view of the joint of Fig. 2; Fig. 4 is a perspective, partially cut-away view of the joint assembled; Fig. 5 is a cross-section view on the line V-V in Fig 1 ; Fig. 6 is a longitudinal cross sectional view of another composite panel; Fig. 7 is a cross sectional view of a joint between adjacent panels of Fig. 6 ; Fig. 8 is a perspective, partially cut-away view of the joint of Fig. 7 ; Fig. 9 is a longitudinal cross sectional view of another composite panel; Fig. 10 is a cross sectional view of a joint between adjacent panels of Fig.

9; and Fig. 11 is a perspective, partially cut-away view of the joint of Fig. 10.

DetaitecL Description Referring to the drawings and initially to Figs 1 and 5 thereof there is ilIustrated a composite panel 1 of an insulated roof guttering system. A joint 2 between two adjacent panels 1A, 1B of the roof guttering system is illustrated in Figs 2 to 4.

Each panel 1 comprises an outer skin 5, an inner skin 6 and a core 7 of insulation material between the skins 5, 6. The outer skin or liner 5 is typically of PVC sheet, approximately 0.5 mm thick. The inner skin 6 is typically of galvanised steel, approximately IXTIW thick. The core 7 may be of any suitable insulation material such as an insulation board ofpolyurethane insulation, fbr example that sold under the trade name Kraftboard. The inner skin 6 is coated with a waterproof membrane 8, typically of PVC material which is bonded to the skin 6 except for a short section 8A (typically 200mm long) at one end which is overlapped onto the membrane 8 of an opposite end of an adjacent panel as will be described in more detail below.

Adjacent panels 1A, 1B are inter-engaged at a joint 2 therebetween to from a guttering system. In this case, the inner skin 6 with the bonded membrane 8 projects laterally of the insulating core 7 to inter-engagc by overlapping onto a membrane-free portion 6A of the inner skin 6 of an adjacent panel 1B. The unbonded membrane section 8A is then overlapped onto the bonded membrane 8 of the panel 1A and sealed.

To form a panel 1 according to the invention the inner skin 6 is nrst cut to a desired flat length. One face of the skin 6 is sprayed with a contact adhesive and lei to cure for 5 to 10 minutes. One side of the membrane 8 is sprayed with the same contact adhesive and is also left to cure. The membrane 8 is then bonded to the skin 6 to form a laminated sheet. This laminated sheet is then formedlprofEed into a required shape such as that illustrated in Fig. 5.

The other side of the inner skia 6 is then sprayed with a composite adhesive. Similarly one side of a pre-cut section of Kraftboazd insulation 7 is also sprayed with the composite adhesive. After curing, the laminated profile inner skin 6 is bonded to the insulation 7. Similarly, a pre-formed outer ski 5 is bonded to the other side of the insulation 7 to form an msulated gutter panel 1 which is a fully composite bonded panel, except for the unbonded area 8A of the membrane 8.

The area 8A is simply left unbonded by omitting contact adhesive between the membrane 8 and the inner skin 6 in this region.

It will be appreciated that the resultant panel 1 is a substantially rigid insulated gutter panel which is readily overlapped as illustrated. On overlapping, the unbonded section 8A of the membrane 8 is overlapped with the bonded section of the membrane 8 of an adjacent panel 1A and heat scaled to form an inter-engagcd overlapped seal at the joint 2 between adjacent panels 1A, IB.

Referring to Figs 6 to 8 there is Hlustated another panel 20 which is sirdar to the panel I descn'bed above and like parts are assigned the same reference umetals. In this case the outer sE 5 parday overlaps the insulating core 7, a portion 5B of the skin 5 projecting laterally from one side to engage in a recess 25 formed by another portion 5A of the outer sidn. A further improved overlapping sealing engagement results.

Refening to Figs 9 to 11 there is Blustrated another panel 30 which is similar to the panel 20 described above with reference to Figs 6 to 8 and like parts are assigned the same reference numerals. In this case the outer skin 5 partially overlaps the insulating core 7. The membrane 8 is a coatnag which is applied over the entire length of the inner skin 6 during manufacture of the panel.

It will be appreciated that any suitable form of inter-engaging/overlapping joint may be used. For example, for enhanoed sealing a joggle-type joint may be provided.

The invention is not limited to the cnbodiments hereinbefoae desicd which may be varied in d tail.

Claims

1. A gutter system compnsingr- at least two composite gutter panels; each composite panel comprising an outer skin, an inner skin and a core of insulation material therebetween ; the inner skin having a waterproof membrane ; adjacent panels being over-lapped at a joint therebetween ; and membrane sealing means for sealing the joint between adjacent panels, on assembly.

2. A gutter system as claimed in claim 1 wherein the membrane sealing means comprises an extension of the waterproof membrane of the inner skin.

3. A gutter system as claimed in claim 2 wherein the membrane sealing means comprises a joint portion of the waterproof membrane of the inner skin.

4. A gutter system as claimed in claim 3 wherein the joint portion is unbonded to overlap, on assembly, with the waterproof membrane of an adjacent panel.

5. A gutter system as daimed in any preceding claim wherein the membrane sealing means is heat sealable at the joint.

6. A gutter system as claimed in any preceding claim wherein the inner skin comprises a metal skin with a membrane bonded thereto.

7. A gutter system as claimed in any preceding claim wherein each panel has a lateral extension of the inner skin at one end for overlapping with the inner skin of an adjacent panel, on assembly.

8. A gutter system as claimed in any preceding claim wherein each panel has a lateral extension of the outer skin at one end for overlapping with the insulation core of an adjacent panel, on assembly.

9. A gutter system as claimed in any preced. ing claim whcrein the inner skins of adjacent panels inter-engage, on assembly, to form a joggle joint.

10-A gutter system substantially as hereinbefore described with reference to the accompanying drawings.

11. A composite gutter panel comprising an outer skin, an inner skin, and a core of insulation material therebetween, the inner skin having a waterproof membrane, the panel having overlapping means for overlapping, on assembly, with another composite gutter panel, and membrane sealing means for sealing the joint between adjacent panels, on assembly.

12. A composite gutter panel as claimed in claim 11 wherein the membrane sealing means comprises an extension of the waterproof membrane of the inner skin.

13. A composite gutter panel as claimed in claim 12 wherein the membrane sealing means comprises a joint portion of the waterproof membrane of the inner skin.

14. A composite gutter panel as claimed in claim I3 wherein the joint portion is unbonded to overlap, on assembly, with the waterproof membrane of an adjacent panel.

15. A composite gutter panel as claimed in any of claims 11 to 14 wherein the inner skin comprises a metal skin with a membrane bonded thereto.

16. A composite gutter panel as claimed in any of claims 11 to 15 having a lateral extension of the inner skin at one end for overlapping with the inner skin of an adjacent panel, on assembly.

I7. A composite gutter panel as claimed in any of claims 11 to 16 having a lateral extension of the outer skin at one end for overlapping with the insulation core of an adjacent panel, on assembly

18. A composite gutter panel as claimed in any of claims I I to 17 wherein the outer skin includes joggle joint forming means which inter-engage on assembly tD form a joggle joint.

19. A composite gutter panel substantiaIly as herembefore described with reference to the accompanying drawings.