GB2469845A

GB2469845A - Thermal insulation structure for conservatory style roofs

Info

Publication number: GB2469845A
Application number: GB0907379A
Authority: GB
Inventors: James Hogg
Original assignee: Individual
Current assignee: Individual
Priority date: 2009-04-30
Filing date: 2009-04-30
Publication date: 2010-11-03
Anticipated expiration: 2029-04-30
Also published as: GB2469845B; GB0907379D0

Abstract

A thennal insulation structure fitted to a conservatory style roof comprising a multilayer composite thin thermal insulator 11, a plural array of elongate battens 14 that supports the insulating layer to form an insulating layer extending across the underside of the roof and a continuous panel 16 on a lower side of the batten array. Preferably the multilayer composite thin thermal insulator comprises two external reflective layers and at least four internal reflective layers each spaced by at least one insulating layer, where the reflective layers are metalised films. The plural array of battens may be in parallel and be mounted across and generally perpendicular to roof frame elements making up the roof frame, where the array may be directed mounted to the frame elements 12 or indirectly mounted so that there is at least one layer of counter battens between the frame elements and the array/insulating layer. Preferably the battens are timber members, the array is mounted to the fence elements using screw fixings and the continuous panel is plasterboard that provides an internal ceiling finish. There may also be external ventilation holes to provide ventilation communication between outside and a ventilation space created between the multi layer composite thin insulator layer and the roof panel. A method of fitting the thermal insulation structure is also claimed.

Description

ROOF MODIFICATION STRUCTURE

The invention relates to a roof modification structure fitted to a conservatory style roof of the type comprising an open frame structure mounting a plurality of panels, and to a method of fabrication of such a structure, especially as an after-market modification in situ.

Conservatories and similar structures are often added as an annex to a house, for example to provide a garden room. A roof for such a structure typically comprises a roof framework of structural members, for example of aluminium or galvanised steel, into which are fitted plural panels at least some of which are translucent/transparent to allow in ambient light. Typical roof panels are polycarbonate sheet.

Polycarbonate roofing systems have been provided to the majority of both timber and UPVC conservatories for at least 20 years. Polycarbonate roof sheets come in various thicknesses, with older conservatories usually having thinner sheet (for example 19 mm), with more modern systems having slightly better performing thicker polycarbonate sheets (up to 50 mm thick).

In many practical situations the polycarbonate roof system is less than ideal.

The majority of the heat gain and heat loss in a conservatory is through the roof system, as it provides very little in the way of insulation. This can make the conservatory structure impractically hot in summer and impractically cold in winter. The present invention is intended to modify such a roof system with a view to greatly reduce heat loss in winter and reduce solar gain in summer, producing a more usable structure for a greater part of the year in varied climate conditions.

Current solutions are directed primarily at reducing solar gain. It is known for example to modify conservatory-style roofs by fitting roof blinds tailored to fit the panels. This can cut glare and help reduce greenhouse effect heating. It is also known to provide inserts into channels between polycarbonate panels to provide a deployable light limiting system to allow a user to achieve a similar effect. Neither of these options provides much in the way of insulation.

In accordance with a first aspect of the invention there is provided a thermal insulation structure fitted to a conservatory style roof of the type comprising an open frame structure mounting a plurality of panels at least some of which allow the transmission of ambient light, the structure comprising, fitted onto an underside of the said roof: a multilayer composite thin thermal insulator; a plural array of elongate battens supporting the multilayer composite thin thermal insulator so that it forms an insulating layer extending across the underside of the rood between the battens and the roof; a continuous panel on a lower side of the batten array.

The resultant structure can be fitted simply in situ to an existing conservatory or like roof, does not require the elements to be specifically tailored to fit in a complex manner, offers the potential for effective insulation which takes up relatively little of the roof space, and presents a lower surface which is continuous to be finished as a ceiling. In effect, it gives the conservatory style roof an internal structural finish akin to that of a conventional room ceiling.

Of course, the fitment of such a structure permanently prevents the transmission of light through the roof. Such a structure might seem therefore contrary to the primary purpose of the roof. However, it has been surprisingly found that for many practical situations the significant mitigation of climate problems conferred by an insulating layer far offsets any potential disadvantage of preventing transmission of light through the roof. For most purposes, in the case of many conservatory style structures, the light through window panels in the walls is sufficient.

The primary insulating component comprises a multilayer composite thin thermal insulator. Such as term will be well understood by a person skilled in the art as referring to a known category of thermal insulating material coming in pliable sheet form with limited thickness, for example less than 100 mm, often less then 50 mm, and especially less than 35 mm, supplied in the form of strips, sheet or other supple panels for the thermal insulation of buildings where space is at a premium, for example in a loft conversion. Such materials comprise multiple layers of thermally reflective material to reduce transmission of heat by radiation, and of insulating material to reduce transmission by conduction.

The reflective layers may be for example metalised films. The reflectivity of the films limits thermal transfer by radiation. The superposition of several spaced metalised films limits exchange by radiation successively in a more effective manner. The interposed insulating layers act to separate such films and limit thermal transfer by conduction. Several known types of interposed layer are known, including layers consisting of fibrous material, such as layers of synthetic fibrous material, for example wadding made of polyester, glass wool, rock wool, hemp wool, sheeps wool etc, woven or non woven fabrics or meshes or nets etc; and layers consisting of cellular materials such as closed-cellular or open-cellular foam, bubble films, etc. Typically, materials comprise at least one and usually two external reflective layers, for example with structural reinforcement incorporated, and an internal multilayer structure comprising one or more of internal reflective layers, fibrous material, and cellular material.

An effective structure might contain two external reflective layers and at least four internal reflective layers each spaced by at least one insulating layer for example of fibrous material or cellular material.

The battens serve to support the insulating layer of multilayer composite thin thermal insulator, and comprise a plural array, for example in parallel, and for example mounted across and generally perpendicular to roof frame elements making up the roof frame. They serve to hold the insulation layer and the lower continuous panel in place and to provide a limited ventilation space.

Two mounting methods can be considered. In a simplest mounting method, the plural array of elongate battens may be directly mounted to the frame elements. In this arrangement, the thin thermal insulator is held directly against the frame elements. In an alternative arrangement, where it might be desirable to space the thin thermal insulator layer further away from the underside of the roof, for example to provide for additional ventilation space, the plural array of elongate battens may be mounted indirectly in that at least one layer of counter battens is first affixed to the underside of the roof, for example along the frame elements, and the thin thermal insulator/cross battens/panel structure is assembled below the counter battens in the manner above described. Where multiple layers of battens are used, it is possible to fix the upper most layer to frame elements and subsequent layer(s) to an adjacent batten array.

The frame elements are typically metal, for example aluminium or mild steel (galvanized or plasticized). The battens are typically timber, and are for example elongate 25 x 38 mm timber members. The battens are preferably fixed to the frame element and/or to each other as applicable by mechanical fixings such as screw fixings.

The roof panels are typically translucent to ambient light, and are for example polycarbonate or similar.

The continuous panel which closes the structure is for example plasterboard to provide a continuous internal ceiling finish.

Optionally, the structure is finished by the provision of external ventilation holes to exploit the ventilation space created between the multi layer composite thin thermal insulator layer and the roof panels. For example, ventilation holes are drilled through a roof structure fillapiece at eaves/gutter level around the roof structure to provide ventilation communication between the external environment and the said ventilation space.

In accordance with the invention in a further aspect, a method of fitment of a thermal insulation structure, particularly as an after market modification, to a conservatory style roof of the type comprising an open frame structure mounting a plurality of panels at least some of which transmit ambient light comprises the steps of fitting on an underside thereof: a multilayer composite thin thermal insulator; a plural array of elongate battens supporting the multilayer composite thin thermal insulator so that it is presented as an insulating layer extending across the underside of the roof between the battens and the roof a continuous panel on a lower side of the batten array.

Two alternative methods of fitment are described.

In a first method, the above elements are fitted directly to the roof frame structure. For example the method comprises the following steps: fixing a layer of multilayer composite thin thermal insulator to an underside of successive roof frame elements of the said roof so that it extends across the roof area, for example by means of a temporary fixing such as double sided tape; positioning a plural array of elongate battens underneath the insulating layer, for example in parallel and for example perpendicular to the roof frame elements, and fixing these to the roof frame elements, for example by means of mechanical fixings such as screws to retain the insulating layer in position; mounting a continuous panel on a lower surface of the batten array.

In an alternative, indirect mounting arrangement counter battens are provided as above described, and the method comprises the steps of: fixing at least one plural array of elongate counter battens to an underside of successive roof frame elements of the said, for example in parallel array and for example parallel and adjacent the roof frame elements; fixing a layer of multilayer composite thin thermal insulator to an underside of the counter batten array so that it extends across the roof area, for example by means of a temporary fixing such as double sided tape; positioning a plural array of elongate primary battens underneath the insulating layer, for example in parallel and for example perpendicular to the roof frame elements, and fixing these to the counter battens and/ or roof frame elements, for example by means of mechanical fixings such as screws, to retain the insulating layer in position; mounting a continuous panel on a lower surface of the primary batten array.

In an optional additional step, the lower continuous panel may be given a suitable ceiling surface finish such as a plaster finish.

In an optional additional step, ventilation holes may be drilled around the roof structure at eaves/gutter level to provide ventilation communication into the space between the roof panels and the insulating layer.

The system as above described is readily fitted to a wide range of existing conservatory roof structures (monopitch, hipped, gable-ended etc.). The system follows the line of the underside of the existing roof structure and is thus typically vaulted with a small level ceiling at the apex. The system can be installed on roofs with opening roof windows, as these may simply be formed around to retain the opening window.

The invention will now be described by way of example only with reference to the accompanying drawings in which: Figure 1 is a representation of a first structural embodiment of the invention; Figure 2 is a representation of a second structural embodiment of the invention.

Figure 1 is a representation of a section through a fitted first structural embodiment of the invention in which an insulation system is fitted to a conservatory style roof in situ. The system is installed as follows.

Ventilation holes (not shown) are drilled through the filer piece at the eaves/gutter level all around the conservatory. These communicate with the space defined between the roof panels and the insulation layer once fitted. The holes are hidden behind the external fixed gutter and cannot be seen from the outside. They are also not visible internally once the system is installed.

Where possible (space permitting) the holes are protected with a wire fly mesh type product is installed to prevent possible insect access.

Following that, an insulation layer, in the embodiment a multilayer composite insulation quilt (II), is temporarily bonded to the underside of the existing roof members (12) using suitable temporary fixings such as steel staples or double sided sticky tape. The purpose of the temporary fixings is just to hold the insulation in place until the timber battens are fixed, which then permanently nips the insulation up tight in position.

Timber battens (14) consisting of 25 x 38 mm timber are then screw fixed into the aluminium/galv steel roof members (12) using hard tipped screws or self tapping screws (or any other appropriate screw). The ceiling is then finished using 9.5mm plasterboard (16) and plaster skim which is screw fixed to the timber battens (14), and may then be painted.

The assembled structure covers and encloses the polycarbonate roof panels (13) and provides much more effective insulation. A ventilation gap (18) is created which allows ventilation to outside via the holes at the eaves/gutter level.

Where the finished ceiling slopes down and abuts the top of the window frames, an expansion joint is installed, which is usually a retained gap of approx 5 mm and filled with paintable mastic.

Figure 2 is a representation of a section through a fitted second structural embodiment of the invention installed in a second manner. The way that the second system can be installed is very similar to the above, but the alternative just creates a wider ventilation gap (28) between the top of the insulation (21) and the underside of the polycarbonate roof sheets (23). This is achieved by firstly installing 25x38 mm timber counter battens (25) to the underside of the roof members (22) instead of installing the insulation directly thereon. These counter battens run up the length of the roof members, so that they cannot be seen from the outside. The insulation (21) is then fixed to the underside of these counter battens. After that the normal cross battens (24) are installed, and the roof is then finished as usual as described above.

The insulation used is a thin composite insulation which is for example either tn-iso super 10 or SF19 superfoil quilt. Other similar insulations are available and can be used.

Claims

CLAIMS1. A thermal insulation structure fitted to a conservatory style roof of the type comprising an open frame structure mounting a plurality of panels at least some of which allow the transmission of ambient light, the structure comprising, fitted onto an underside of the said roof: a multilayer composite thin thermal insulator; a plural array of elongate battens supporting the multilayer composite thin thermal insulator so that it forms an insulating layer extending across the underside of the roof between the battens and the roof a continuous panel on a lower side of the batten array.
2. A structure in accordance with claim I wherein the multilayer composite thin thermal insulator has a thickness of less than 100 mm.
3. A structure in accordance with claim 2 wherein the multilayer composite thin thermal insulator has a thickness of less than 35 mm.
4. A structure in accordance with any preceding claim wherein the multilayer composite thin thermal insulator comprises at least one external reflective layer, for example with structural reinforcement incorporated, and an internal multi layer structure comprising one or more of: internal reflective layers, fibrous insulating layers, and cellular insulating layers.
5. A structure in accordance with claim 4 wherein the multilayer composite thin thermal insulator comprises two external reflective layers and at least four internal reflective layers each spaced by at least one insulating layer.
6. A structure in accordance with claim 5 wherein the reflective layers are metalised films.
7. A structure in accordance with any preceding claim wherein the battens comprise a plural array, for example in parallel, and for example mounted across and generally perpendicular to roof frame elements making up the roof frame.
8. A structure in accordance with claim 7 wherein the plural array of elongate battens is directly mounted to the frame elements.
9. A structure in accordance with claim 7 wherein the plural array of elongate battens is mounted indirectly in that at least one layer of counter battens is first affixed to the underside of the roof, for example along the frame elements, and the thin thermal insulator/cross battens/panel structure is assembled below the counter battens.
10. A structure in accordance with any preceding claim wherein the battens are timber.
11.A structure in accordance with claim 10 wherein the battens are elongate 25 x 38 mm timber members.
12.A structure in accordance with any preceding claim wherein the battens are fixed to roof frame elements and/or to each other as applicable by mechanical fixings such as screw fixings.
13.A structure in accordance with any preceding claim wherein the roof panels which allow the transmission of ambient light are translucent polycarbonate panels.
l4.A structure in accordance with any preceding claim wherein the continuous panel which closes the structure is plasterboard to provide a continuous internal ceiling finish.
l5.A structure in accordance with any preceding claim further comprising external ventilation holes to provide ventilation communication between the external environment and the ventilation space created between the multi layer composite thin thermal insulator layer and the roof panels
16.A method of fitment of a thermal insulation structure, particularly as an after market modification, to a conservatory style roof of the type comprising an open frame structure mounting a plurality of panels at least some of which transmit ambient light, the method comprising the steps of fitting on an underside thereof: a multilayer composite thin thermal insulator; a plural array of elongate battens supporting the multilayer composite thin thermal insulator so that it is presented as an insulating layer extending across the underside of the roof between the battens and the roof; a continuous panel on a lower side of the batten array.
17. A method in accordance with claim 16 comprising the steps of: fixing a layer of multi layer composite thin thermal insulator to an underside of successive roof frame elements of the said roof so that it extends across the roof area, for example by means of a temporary fixing such as double sided tape; positioning a plural array of elongate battens underneath the insulating layer, for example in parallel and for example perpendicular to the roof frame elements, and fixing these to the roof frame elements, for example by means of mechanical fixings such as screws to retain the insulating layer in position; mounting a continuous panel on a lower surface of the batten array.
18. A method in accordance with claim 16 comprising the steps of: fixing at least one plural array of elongate counter battens to an underside of successive roof frame elements of the said, for example in parallel array and for example parallel and adjacent the roof frame elements; fixing a layer of multi layer composite thin thermal insulator to an underside of the counter batten array so that it extends across the roof area, for example by means of a temporary fixing such as double sided tape; positioning a plural array of elongate primary battens underneath the insulating layer, for example in parallel and for example perpendicular to the roof frame elements, and fixing these to the counter battens and! or roof frame elements, for example by means of mechanical fixings such as screws, to retain the insulating layer in position; mounting a continuous panel on a lower surface of the primary batten array.
l9.A method in accordance with one of claims 16 to 18 wherein in an additional step, the lower continuous panel is given a suitable ceiling surface finish such as a plaster finish.
20.A method in accordance with one of claims 16 to 19 wherein in an additional step, ventilation holes are drilled around the roof structure at eaves!gutter level to provide ventilation communication from ambient into the space between the roof panels and the insulating layer.