IE85664B1

IE85664B1 - A roof panel

Info

Publication number: IE85664B1
Application number: IE2006/0442A
Authority: IE
Inventors: Carolan James; Flynn Gregory
Original assignee: Kingspan Research And Developments Limited
Filing date: 2006-06-13
Publication date: 2011-01-05

Abstract

ABSTRACT A roof panel for a flat or low pitch roof comprises an inner metal sheet liner or decking 2, an outer liner scrim 3 and a body 4 of insulation therebetween. The scrim 3 for receiving a waterproof membrane may be a glass fibre scrim bonded to cellulose/polyester tissue or a bitumen—impregnated scrim.

Description

A Roof Panel Introduction This invention relates to a roof panel for forming a low pitch or ﬂat roof.

Insulated membrane based roof decking systems are known. One of the problems associated with known systems is the difﬁculty in providing a panel which can be used on site with a wide range of different site-applied waterproof membranes.

This invention is directed towards providing a roof panel which will address this problem.

Statements of Invention According to the invention there is provided a roof panel for forming a low pitch or ﬂat roof, comprising an inner metal sheet liner, an outer liner, a body of insulation material between the inner liner and the outer liner, wherein the outer liner comprises a scrim for reception of a waterproof covering, the scrim comprising a ﬁber glass scrim applied to a tissue, the tissue with applied fiber glass scrim has a weight per unit area of from 70 to 100 the scrim may contain from 2 to 4 threads per cm warp, and the scrim may contain from 1 to 3 threads per cm weft.

Preferably the scrim has a weight per unit area of 85 to 95 and preferably approximately 90 g/m2 of panel.

In one embodiment the scrim contains approximately 3 threads per cm warp and 2 threads per cm weﬂ.

In one embodiment the scrim is formed from a glass ﬁber of approximately 34 D’tex.

Also described is a scrim comprising a bituminous material. The scrim may comprise a support ﬁbre with bitumen coated or impregnated therein. The ﬁbres may be cellulose/textile ﬁbres.

The bituminous scrim may have a weight per unit area of from 480 to 500 g/m2.

In one embodiment the scrim is for reception of a waterproof membrane.

Also described is a continuous method for producing a roof panel comprising the steps of:- leading an inner metal sheet linear to a lay-down bed; laying down a liquid foam reactant mixture onto the inner liner; leading a scrim over the foam; expanding the foam to form an insulating roof panel, the scrim forming a substrate for reception of a waterproof covering.

In one case the scrim is a ﬁbre glass scrim having a weight per unit area of from 70 to 100 g/m2.

In another case the scrim is a bituminous scrim having a weight per unit area of from 480 to 500 g/m2.

Further described is a continuous method for producing a roof panel comprising the steps 01’:- leading an inner liner to a lay-down bed; laying down a liquid foam reactant mixture onto the inner liner; leading a tissue with applied ﬁber glass scrim having a weight per unit area of from 70 to g/m2 of board over the foam; expanding the foam to form an insulating roof panel, the scrim forming a substrate for reception of a waterproof membrane.

Also described is a roof panel when manufactured by a method of the invention.

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 joint between roof panels according to the invention; Fig. 2 is a perspective view from above of a roof panel of Fig. 1; Fig. 3 is a plan View of a ﬁber glass scrim used in the panel of the invention; Fig. 4 is a cross-sectional view of a joint between alternative roof panels according to the invention; Fig. 5 is a perspective View from above of the roof panel of Fig. 4; Fig. 6 is a plan View of a bituminous scrim used in the panel of Figs. 4 and 5; Fig. 7 is a perspective view of another panel of the invention with a ﬁbre glass scrim; Fig. 8 is a cross-sectional View of a joint between two of the panels of Fig. 7; Fig. 9 is a perspective View of a ﬁirther panel with a bituminous scrim; and Fig. 10 is a cross-sectional view of a joint between two of the panels of Fig. 9.

Detailed Description Referring to Figs. 1 and 2 there is illustrated a roof panel according to the invention for use in forming a low pitch or ﬂat roof.

The roof panel 1 comprises a proﬁled inner metal sheet liner or decking 2, an outer liner 3, and a body 4 of insulation between the inner liner 2 and outer liner 3. A waterproof membrane (not shown) is bonded to the outer scrim on site.

The inner liner 2 which may be of painted galvanised steel is formed with trapezoidal portions for improved mechanical and insulation performance.

The insulation may be of any suitable foam material such as polyisocyanurate foam.

The outer liner 3 comprises a polyester! cellulose tissue with an applied scrim for reception of a waterproof membrane which is bonded on site to the outer liner 3. The tissue with applied scrim in this case has the following properties: Yarn Warp 34 tex glass ﬁbre Yarn Weft 34 tex glass ﬁbre Construction 3 threads per cm Warp threads per cm weft Tissue 65 gsm polyester / cellulose Binder externally plasticized polyvinyl acetate Tensile Strength Warp: 54 daN/5cm Tensile Strength Weft : 34 daN/5cm Density 90.5 gsm Referring to Fig. 3 the scrim is formed from warp threads 6 and weft threads 7 which are interconnected to form a matrix as diagrammatically illustrated.

Referring to Fig. 4 and 5 there is illustrated another roof panel 10 according to the invention for use in forming a low pitch or ﬂat roof.

The roof panel 10 comprises a proﬁled inner metal sheet liner or decking 12, an outer liner scrim 13, and a body 14 of insulation between the inner liner 12 and outer liner 13. A waterproof membrane (not shown) is bonded to the outer scrim 13 on site.

The inner liner 12 which may be of painted galvanised steel is formed with trapezoidal portions for improved mechanical and insulation performance.

The insulation 14 may be of any suitable foam material such as polyisocyanurate foam.

The outer scrim 13 [Fig. 6] in this case comprises a bituminous material comprising a support ﬁbre of cellulose or textile with bitumen coated or impregnated therein. The bituminous scrim has a Weight of from 480 to 500 g/m2.

Referring to Figs. 7 and 8 there is illustrated an alternative panel 20 according to the invention with a ﬁbre glass scrim 3 outer as described above.

Referring to Figs. 9 and 10 there is illustrated another panel 30 with a bituminous scrim outer 13 as described above.

The major advantage of using a scrim to form the outer liner is that it provides a substrate to which any suitable waterproof membrane may be applied on site. The membrane may be of rubber, ﬂexible plastics or PVC and may be heat and/or adhesively bonded to the upper exposed face of the panels. Thus, an installer can use any suitable membrane.

The panels 1 are ﬁxed to underlying supports or purlins and/or adjacent panels by means of fasteners or ﬁxing screws 5. Alternatively, the fixings may be of the self-boring type.

The side edges of panel may be proﬁled to provide any required joint detail.

The roof panel of the invention is manufactured on a continuous line. The inner metal liner 2 is proﬁled and then led along a conveyor to a lay-down bed at which liquid foam reactants are laid across the upper face of the liner 2. The scrim 3 is led from a supply reel over the foam. The assembly thus formed is heated in an oven to allow the foam to expand.

The invention is not limited to the embodiments hereinbefore described which may be varied in construction and detail.

Claims

1. Claims A roof panel for forming a low pitch or flat roof, comprising an inner metal sheet liner, an outer liner, a body of insulation material between the inner liner and the outer liner, wherein the outer liner comprises a scrim for reception of a waterproof covering, the scrim comprising a fiber glass scrim applied to a tissue, the tissue with applied ﬁber glass scrim has a weight per unit area of from 70 to 100 g/m2 of panel, the scrim contains from 2 to 4 threads per cm warp, and the scrim contains from 1 to 3 threads per cm Weft. A panel as claimed in claim 1 wherein the tissue of polyester / cellulose. A panel as claimed in claim 1 or 2 wherein the weight per unit area of the tissue with applied ﬁber glass scrim is from 85 to 95 g/m2 of panel. A panel as claimed in any of claims 1 to 3 wherein the weight per unit area of the tissue with applied ﬁber glass scrim is approximately 90 g/m2 of panel. A panel as claimed in any preceding claim wherein the scrim contains approximately 3 threads per cm warp and 2 threads per cm weft. A panel as claimed in any preceding claim wherein the scrim is formed from a glass ﬁber of approximately 34 D’tex. A panel as claimed in any preceding claim wherein the scrim is for reception of a waterproof membrane. A roof panel substantially as hereinbefore described with reference to the accompanying drawings.