WO2003046307A1

WO2003046307A1 - Modular element and method to insulate and ventilate a roof

Info

Publication number: WO2003046307A1
Application number: PCT/IB2002/004949
Authority: WO
Inventors: Valerio Pontarolo
Original assignee: Pontarolo Engineering S.R.L.
Priority date: 2001-11-30
Filing date: 2002-11-26
Publication date: 2003-06-05
Also published as: AU2002347494A1; ITUD20010195A1

Abstract

Modular element (10) to insulate and ventilate a roof, comprising an upper surface (11) provided with a plurality of corners (12, 13, 14, 15) and able to be arranged, during use, substantially parallel to the surface of a pitch (40) of the roof, and a plurality of supporting pillars (21), able to keep the upper surface (11) at a determinate distance from the surface of the pitch (40), to form at least a ventilation chamber (25) below the upper surface (11). Coupling means (32, 33, 34, 35) are arranged at least in correspondence with the corners (12, 13, 14, 15) to define a watertight seal when, during use, the modular element (10) is associated with other identical modular elements (10), and to prevent water from entering the ventilation chamber (25) in correspondence with the corners (12, 13, 14, 15).

Description

MODULAR ELEMENT AND METHOD TO INSULATE AND VENTILATE A ROOF

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FIELD OF THE INVENTION

The invention refers to a modular element, or module, and to a method to insulate and ventilate a roof. Each module is able to be arranged, in cooperation with other, identical modules, between the pitches and tiles of the roof, both to prevent water which might filter through the tiles from reaching the pitches, and also to create at least a ventilation chamber below the tiles. Advantageously each module is a parallelogram seen in plane view and, in correspondence with the corners and sides, has coupling elements which define, once coupled with those of the adjacent modules, a watertight seal, in the sense that it is impossible for rainwater to filter between the modules and reach the ventilation chamber below, and hence the pitch of the roof, as the water flows, whether quickly or slowly, from the highest ridge of the roof to the lowest eaves.

BACKGROUND OF THE INVENTION It is known that to insulate and ventilate the roof of a building it is necessary, if not indispensable, to put between the slopes or pitches of the roof and the covering tiles, whatever shape they may be, at least an element of strong material, heat insulating and shaped in such a manner as to create one or more ventilation chambers arranged in the longitudinal direction of the roof, that is, between the ridge of the roof and the eaves, through which the air can circulate freely.

It is known a ventilating element of composite material and undulating in shape, which defines a plurality of longitudinal ventilation channels, which substantially follow the arrangement of the tiles. Normally, the coupling of the insulating elements is achieved by making them partly overlap, along their four sides. These conventional elements, however, have the following disadvantages. First of all they do not offer a sufficient level of ventilation, since the undulating wall itself is in contact both with the tiles above and also with the pitch below. Moreover, in order to couple along the edges, they have to be at least partly overlapping, so that to cover a particular surface of the roof, the surface of the elements has to be greater than the surface of the roof. Furthermore, they are not suitable to be covered with a concrete cast which would keep them amalgamated and define a uniform layer on which to lay the tiles.

It is also known a modular element, made of plastic material, shaped like a four-legged stool with the legs arranged in correspondence with the corners. However, this conventional modular element has the disadvantage that it does not offer any watertight seal, when it is coupled with other identical modular elements. In fact, nothing is provided to guarantee a coupling between the different modular elements which will prevent the water from filtering from the top downwards, especially in correspondence with the corners, even though, during use, all the adjacent modular elements are covered by a layer of concrete, which, as is known, does not offer any watertight seal.

It is also known a system to ventilate the roof made by laying a layer of wood on the underlying pitch. The layer of wood consists of planks or panels located adjacent to each other and kept separate from the pitch by squared timbers of various height. This system does not offer any watertight seal either, which would require a layer of waterproof material such as tar to be spread on top, or a sheath of tar or suchlike suitable for the purpose; such contrivances are burdensome both in terms of time required for laying, and also in economic terms.

US-A-3, 501, 878 discloses sound and heat insulating panels having a regular geometric shape, wherein a plurality of hollow protuberances are provided to strengthen the panels and also to form air cavities when an insulating layer of cork and asphalt is adhered thereto. A moisture repellant surface is disposed adjacent the insulating layer to provide an integral lightweight and effective insulation structure. To joint together two panels, the outmost row of the protuberances on each side of one panel are interlocked into the hollows of the corresponding outmost row of protuberances of the adjacent panel. This known panels have the disadvantages to utilise an entire row of protuberances to realise the joining between two adjacent panels and not to provide for any means which achieve a watertight seal also in the zones in correspondence with the corners of the panels.

Applicant has devised, designed and embodied the present invention to overcome the shortcomings of the state of the art and to obtain a modular element and a method which have innovative characteristics.

SUMMARY OF THE INVENTION The invention is set forth and characterized in the main claims, while the dependent claims describe other innovative characteristics of the invention.

One purpose of the invention is to achieve a modular element to insulate and ventilate roofs, which is simple to make and lay, and which at the same time defines at least a ventilation chamber between the tiles and the pitch below. This modular element must also be provided with coupling means such as to achieve a watertight seal even in the points where adjacent modules are coupled, including the zones in correspondence with the corners.

Another purpose of the invention is to achieve advantageously a modular element wherein the dew point, that is, the condensation of the air arriving from the rooms below the roof, occurs precisely in the ventilation chamber and therefore not in other parts of the building, with a consequent stagnation of humidity and the formation of mold in the ceilings. A further purpose of the invention is to perfect a method to insulate and ventilate roofs based on using the new modular element as described.

In accordance with these purposes, the modular element according to the invention comprises an upper surface able to be arranged, during use, substantially parallel to the plane of a pitch of the roof and a plurality of supporting pillars, able to keep said upper surface at a determinate distance from said pitch, and able to define a ventilation chamber or interspace below the upper surface. Coupling means are arranged in correspondence with the corners and the sides of the upper surface to define a watertight seal when, during use, the modular element is associated with other, identical modular elements, and to prevent the water from entering into the ventilation chamber in correspondence with the corners. The upper surface, however, can be flat, curved, concave, convex or formed by a number of small domes .

Advantageously the upper surface of the modular element is substantially a parallelogram, for example a square, a rectangle or a rhombus, and is provided with four sides and four corners, but can also assume other shapes with more or less than four sides and corners and with different shapes of the various elements. The afore-said coupling means comprise three upper protrusions made on three of the four corners and are higher than the edges of the upper plate. A platelet, substantially parallel to the upper wall, is made on the fourth corner, protruding outwards with respect to the edges of the upper plate. During use, the platelet of one modular element is able to be arranged above and advantageously in contact with the three protrusions made on the adjacent corners of the other modular elements . The upper surface of the modular element has its lateral edges equal in pairs. A first pair of edges, adjacent to each other, are each provided with a lateral wing advantageously inclined downwards and protruding outwards, while the other two edges each comprise a straight profile which is able to couple during use with a corresponding lateral wing of an adjacent modular element.

The supporting pillars can be arranged both regularly with respect to the upper surface, in a matrix of lines and columns, and also irregularly, at random and asymmetrically. They are hollow inside, comprise central pillars shaped substantially like a truncated cone, corner pillars and edge pillars and can assume different shapes. All the pillars are closed in the part which rests on the pitch; moreover, the edge pillars and the corner pillars are also closed vertically, over their whole perimeter, so as to obtain what are in practice watertight containers.

The height of the modular element is chosen according to the parameters of the roof which is to be ventilated and possibly using the Glaser diagram, so that the dew point is located inside the ventilation chamber, in such a manner that the excess humidity is removed. Advantageously said height is comprised between about 1 and 20 cm. The method to insulate and ventilate a roof using a plurality of modular elements according to the invention provides a step wherein the modular elements are arranged, associated one with the other, between the pitch of the roof to be ventilated and the relative tiles, so as to achieve a first insulating layer with a single ventilation chamber between the pitch and the tiles.

Above the interspace formed with the modular elements, a cast of concrete is made on which, once it has set, the tiles are laid.

BRIEF DESCRIPTION OF THE DRAWINGS These and other characteristics of the invention will be apparent from the following description of a preferential form of embodiment, given as a non-restrictive example with reference to the attached drawings wherein: fig. 1 is a plane view of a modular element according to the invention; fig - 2 is a front view of the modular element in fig. 1; fig . 3 is a prospective view of the modular element in fig. 1; fig . 4 is a first enlarged detail of fig. 3 showing a first corner of the modular element; fig . 5 is a second enlarged detail of fig. 3 showing a second corner of the modular element; ffiigg.. 6 6 is a third enlarged detail of fig. 3 showing a third corner of the modular element; fig . 7 is a fourth enlarged detail of fig. 3 showing a fourth corner of the modular element; fig . 8 is a plane view of four modular elements according to the invention, attached to each other; fig . 9 is a lateral view of the modular elements in fig. 8; fig. 10 is a view from above of an enlarged detail of fig. 8, showing the meeting point of the corners of the four modular elements; fig. 11 is a side view, partly in section, of a modular element according to a variant; figs. 12 and 13 are plane views of combinations of modular elements according to the invention, with different shapes of the various elements; figs. 14, 15, 16 and 17 are side views, partly in section, of some variants of the modular element shown in fFig. 1, wherein the upper surface is curved, concave or convex; figs. 18, 19 and 20 are plane views of other variants of the modular element shown in fig. 1, wherein the supporting pillars are limited in number and arranged in different configurations. DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT With reference to figs. 1 and 2, a modular element or module 10 according to the invention comprises a structure made of plastic material, for example by molding, with a substantially plane upper surface 11 and substantially square when seen in a plane view. According to a variant, the module 10 can have a rectangular, rhomboid or hexagonal shape or with different geometric types adjacent to each other, some of which are shown in figs. 12 and 13.

The upper surface 11 defines four right-angled corners 12, 13, 14 and 15 and four lateral edges or sides 17, 18, 19 and 20.

From the upper surface 11 a plurality of supporting pillars or legs 21 extends downwards.

The module 10 has a side of about half a metre and a height comprised between about 1 and 20 cm, chosen according to the type of roof on which the module 10 has to be installed.

The pillars 21 are arranged regularly in a matrix of lines and columns, they are hollow inside and are of three types: the central pillars 21a, distant from the edges 17, 18, 19 and 20, are like a truncated cone, with the tapered end facing downwards; the corner pillars 21b, arranged in correspondence with the four corners 12, 13, 14 and 15, are substantially equal to a quarter of the central pillars 21a; the edge pillars 21c, arranged along the lateral edges 17, 18, 19 and 20 and distant from the corners 12, 13, 14 and 15, are substantially equal to half the central pillars 21a.

The pillars 21b and 21c are provided with front walls 22 substantially orthogonal to the upper plate 11, which make watertight the inner cavities of the pillars 21b and 21c, defined by their lateral walls.

The pillars 21 are provided inside and towards the bottom with transverse reinforcement ribs 23, and have elements 23a able to house attachment members such as screws or nails, advantageously equipped with appropriate washers, which allow to clamp the module 10 on the pitch of the roof.

Reinforcement ribs 24 are also made on the lower part of the wall 11 between the different pillars 21.

The number and arrangement of the pillars 21 can vary according to the size of the module 10 and the load they have to support. Some examples of how the pillars 21 can be arranged are shown in figs. 18, 19 and 20.

The plurality of pillars 21 defines a ventilation chamber 25, which is open on the four sides of the module 10 and allows the air to circulate freely below the upper surface 11. The adjacent lateral edges 17 and 20 are equal and each comprises a lateral fin 26, inclined downwards and protruding outwards (figs. 1, 2 and 4).

The adjacent lateral edges 18 and 19 are equal and each comprises a straight profile 27, which is able to couple, during use, with a corresponding lateral fin 26 of an adjacent module 10.

In correspondence with each corner 12, 13, 14 and 15 each module 10 is provided with a coupling element 32, 33, 34 and respectively 35. When several modules 10 are coupled together as shown in figs. 8, 9 and 10, the coupling elements 32, 33, 34 and 35 define a watertight seal which prevents the water from penetrating from the top towards the ventilation chamber 25, also at the convergence and meeting points of the corners of four modules 10.

To be more exact, the coupling elements 33 and 35 (figs. 5 and 7) each consist of an upper protrusion, higher by some millimetres than the profiles 27 of the edges 18 and 19, which has a substantially S-shaped profile. Once four modules 10 are coupled, the two coupling elements 33 and 35 are specular to each other (fig. 10) .

The coupling element 34 consists of an upper protrusion as high as the coupling elements 33 and 35 and having a substantially L-shaped profile with equal sides (fig. 6) . The coupling element 34 is able to be arranged during use between the coupling elements 33 and 35 and in close contact therewith (fig. 10) .

The coupling element 32 (fig. 4), on the contrary, consists of a platelet substantially parallel to the upper surface 11 and protruding outwards with respect to the edges 17 and 20. The coupling element 32 is able to be arranged during use above and in contact with the other three coupling elements 33, 34 and 35 (fig. 10) . The closed edge pillars 21b and 21c and the lateral attachment fins 26 are arranged so that the water, as it falls, flows in the direction of the attachment, from the edge 19 to the edge 17 and from the edge 18 to the edge 20 and not vice versa (fig. 8), and the combination of the four coupling elements from 32 to 35 in practice achieve a watertight seal.

Each module 10 advantageously has one or more arrows 36, impressed on the upper surface 11, which indicate to the user the correct direction in which it is to be laid. The method according to the invention, to ventilate a roof comprising at least a pitch 40 (fig. 9) and tiles 41, provides that the modules 10 as described heretofore are arranged above the pitch 40, with the arrows 36 facing towards the eaves of the roof. Each module 10 is attached to the adjacent ones, arranging the fins 26 of its edges 17 and 20 above the straight profiles 27 of the edges 18 and 19 of the other two modules 10 adjacent thereto.

By arranging the modules 10 to cover the pitch 40 we thus achieve an insulating layer with a single large ventilation chamber 25, open at the four sides and protected, thanks to the coupling made by the elements 32, 33, 34 and 35, from the water which could arrive unexpectedly from above, despite the presence of the tiles 41. Above the modules 10 a layer of concrete 42 is then cast, onto which the tiles 41 are laid when it has set. The concrete, also settling into the cavities of each pillar 21, consolidates the coupling between the different modules 10 and anchors them to the pitch 40 below. According to a variant, shown in fig. 11, between the modules 10 and the pitch 40 a layer of insulating material 43 is advantageously laid, for example polystyrene. In this case, the height of the modules 10 and the thickness of the layer 43 are chosen according to the characteristics of heat insulation required.

It is clear that modifications or additions of parts can be made to the module 10 and method as described heretofore, without departing from the field and scope of the present invention.

It is also clear that, although the invention has been described with reference to a specific example, a skilled person shall certainly be able to achieve many other equivalent forms thereof, all of which shall come within the field and scope of the present invention.

Claims

CLAIMS 1. Modular element (10) to insulate and ventilate a roof, comprising an upper surface (11) having a substantially polygonal shape defining at least four corners (12, 13, 14 15) and able to be arranged, during use, substantially parallel to the surface of a pitch (40) of the roof, and a plurality of supporting pillars (21) , able to keep said upper surface (11) at a determinate distance from said surface of the pitch (40) , to form at least a ventilation chamber (25) below said upper surface (11) , characterized in that coupling means (32, 33, 34, 35) are arranged at least in correspondence with said corners (12, 13, 14, 15) to define a watertight seal when, during use, said modular element (10) is associated with other identical modular elements (10) , and to prevent water from entering said ventilation chamber (25) in correspondence with said corners (12, 13, 14, 15), said coupling means comprising at least three upper protrusions (33, 34, 35) made on at least three of said at least four corners (12, 13, 14 15) , higher than the edges (18, 19) of said upper surface (11) , and at least a platelet (32) substantially parallel to said upper surface (11) and made on one of said corners (12) , protruding outwards with respect to the edges (17, 20) of said upper surface (11) .

2. Modular element as in claim 2, characterized in that said platelet (32) is able to be arranged during use above said three protrusions (33, 34, 35).

3. Modular element as in claim 1 or 2, characterized in that two of said upper protrusions (33, 35) have a substantially S-shaped profile.

4. Modular element as in claim 1, 2 or 3, characterized in that one of said upper protrusions (34) has a substantially L-shaped profile.

5. Modular element as in any claim hereinbefore, characterized in that said pillars (21) are arranged regularly with respect to said upper surface (11) in a matrix of lines and columns, are hollow inside and comprise central pillars (21a) shaped substantially like a truncated cone, corner pillars (21b) each substantially equal to a quarter of one of said central pillars (21a) , and edge pillars (21c) each of which is substantially equal to half of one of said central pillars (21a) .

6. Modular element as in any claim from 1 to 4 inclusive, characterized in that said pillars (21) are arranged either in correspondence with said corners (12, 13, 14, 15) so as to form corner pillars (21b), or along the edges (17, 18, 19, 20) of said upper surface (11) so as to form edge pillars (21c), or distant from said edges (17, 18, 19, 20) and from said corners (12, 13, 14, 15), or according to any combination whatsoever.

7. Modular element as in claim 5 or 6, characterized in that said corner pillars (21b) and said edge pillars (21c) are provided with front walls (22) substantially orthogonal to said upper surface (11) .

8. Modular element as in claim 5, 6 or 7, characterized in that said pillars (21) are provided inside with reinforcement transverse ribs (23) .

9. Modular element as in any claim from 5 to 8 inclusive, characterized in that said pillars (21) are provided inside with elements (23a) to house attachment members such as screws, nails or otherwise, to attach said modular element (10) to said pitch (40) .

10. Modular element as in any claim hereinbefore, characterized in that said upper surface (11) is plane, concave or convex.

11. Modular element as in any claim hereinbefore, characterized in that two first adjacent lateral edges (17, 20) of said upper surface (11) are substantially equal to each other and each comprise a lateral fin (26) , inclined downwards and protruding outwards .

12. Modular element as in claim 11, characterized in that two second adjacent lateral edges (18, 19) of said upper surface (11) are substantially equal to each other and each comprise a straight profile (27) which is able to couple during use with a corresponding lateral fin (26) of an adjacent modular element (10) .

13. Modular element as in claim 12, characterized in that, once coupled during use, said edges (17, 18, 19, 20) are able to oblige the water, flowing from the ridge of the roof to the eaves, to flow always above said upper surface (11) without passing into the ventilation chamber (25) below.

14. Modular element as in any claim hereinbefore, characterized in that the distance between said upper surface (11) and said surface of the pitch (40) is chosen according to the parameters of the roof, the characteristics of insulation and ventilation required and the Glaser diagram, so that the dew point is located inside said ventilation chamber (25) .

15. Modular element as in claim 15, characterized in that said distance is comprised between about 1 and 25 cm.

16. Method to insulate and ventilate a roof using a plurality of modular elements (10) as in any one of the claims hereinbefore, characterized in that it comprises a step of arranging said modular elements (10) , associated one with the other, between a pitch (40) of the roof and the relative tiles (41) , to achieve a first insulating layer with a single ventilation chamber (25) between said pitch

(40) and said tiles (41), and so that also between the corners (12, 13, 14, 15) and the edges (17, 18, 19, 20) of adjacent modular elements (10) a watertight seal is achieved which will prevent water from reaching said ventilation chamber (25) .

17. Method as in claim 16, characterized in that above said modular elements (10) a cast of concrete (42) is poured onto which, once it has set, said tiles (41) are laid.

18. Method as in claim 16 or 17, characterized in that a second layer of insulating material (43) is achieved between said modular elements (10) and said pitch (40) .