Title:
Roof System
Kind Code:
A1


Abstract:
A roof system comprises a lower layer of composite insulating panels (2), a protective barrier layer (3) and an upper decorative layer (4) which provides a roof garden. The panels (2) comprise a profiled internal sheet (5), a generally flat external sheet (6) with an insulating core (7) therebetween. The panels (2) provide a mechanically strong roof structure to support the garden layer (4). The panels (2) are protected by a roof barrier membrane (11).



Inventors:
Carolan, James (County Cavan, IE)
Flynn, Gregory (County Louth, IE)
Application Number:
11/991316
Publication Date:
05/28/2009
Filing Date:
09/06/2006
Assignee:
KINGSPAN RESEARCH AND DEVELOPMENTS LIMITED (County Cavan, IE)
Primary Class:
International Classes:
E04B7/18; E04B7/00
View Patent Images:
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Primary Examiner:
HOLLOWAY, JASON R
Attorney, Agent or Firm:
JACOBSON HOLMAN PLLC (Washington, DC, US)
Claims:
1. 1-29. (canceled)

30. A roof system comprising a support layer comprising a composite insulated panel of the type having a profiled sheet and a generally flat sheet with an insulating core between the profiled sheet and the flat sheet; and a barrier layer applied to the generally flat sheet of the support layer for reception of an upper decorative layer.

31. The system as claimed in claim 30 wherein the barrier layer comprises a root barrier membrane.

32. The system as claimed in claim 30 wherein the decorative layer comprises a growing medium for plants and the like.

33. The system as claimed in claim 30 wherein the decorative layer is arranged to cover only a portion of the top face of the composite insulating panels.

34. The system as claimed in claim 30 wherein the decorative layer comprises a water receiving layer.

35. The system as claimed in claim 30 wherein the decorative layer comprises stones and/or sand and/or gravel.

36. The system as claimed in claim 30 wherein the decorative layer comprises a drainage, aeration and water storage layer.

37. The system as claimed in claim 36 wherein the drainage, aeration and water storage layer comprises a top face and a plurality of recessed wells.

38. The system as claimed in claim 37 wherein the recessed wells project downwardly to contact an underlying surface and to space the top face apart from the underlying layer.

39. The system as claimed in claim 30 wherein the decorative layer comprises a permeable membrane.

40. The system as claimed in claim 39 wherein the permeable membrane is laid on top of the drainage, aeration and water storage layer.

41. The system as claimed in claims 39 wherein the permeable membrane comprises a geotextile fabric.

42. The system as claimed in claim 32 wherein the planting medium comprises soil or peat or sand, or any suitable mixture thereof.

43. The system as claimed in claim 30 comprising drainage means.

44. The system as claimed in claim 30 wherein the panels are connected to supporting external and/or internal walls.

45. The system as claimed in claim 30 wherein the root barrier layer is connected to the panels by adhesive or other suitable fixing means.

46. The system as claimed in claim 30 wherein the barrier layer is connected to the external walls.

47. The system as claimed in claim 44 comprising a metal coping for connection to the external walls.

48. The system as claimed in claim 30 comprising a decorative layer retention device to define the perimeter of the decorative layer.

49. The system as claimed in claim 30 wherein the profiled sheet of the composite insulated pane defines a plurality of channels extending longitudinally along the length of the panel.

50. The system as claimed in claim 49 wherein the channels are of generally trapezoidal shape comprising a generally flat base and side walls which extend from and diverge outwardly from the base.

51. The system as claimed in claim 50 wherein the side walls of the trapezoidal formations are stepped side-walls.

52. The system as claimed in claim 50 wherein the profiled sheet has transversely extending reinforcing ribs.

53. The system as claimed in claim 30 wherein the profiled sheet has a first overlap portion on one side and a second overlap portion on the opposite side, the first overlap portion being substantially free of insulating core, the side edge of the insulating core at the first overlap portion having a first inclined wedge face and the side edge of the insulating core at the second overlap portion having a second inclined wedge face which is oppositely directed to the first inclined wedge face at the first overlap portion, the overlap portions and the wedge faces of the insulating core of adjacent like panels being interengageable on assembly.

54. The system as claimed in claim 53 wherein the profiled sheet overlap portions are defined by part trapezoidal portions.

55. The system as claimed in claim 30 wherein the generally flat or second sheet has a second sheet first overlap portion on one side and a second sheet second overlap portion on the opposite side.

56. The system as claimed in claim 55 wherein the overlap portions comprise profiled portions of the external sheet.

57. The system as claimed in claim 55 wherein the second sheet has an outer male projecting part and an inner recess part on one side, and a corresponding outer recess part and projecting inner male part respectively on the opposite side of the panel.

Description:

INTRODUCTION

The invention relates to a roof having an upper decorative layer.

In one current approach a decorative layer such as a garden is installed onto a flat roof. However, there are several problems with conventional systems including excess loading on the roof, water retention in periods of rainfall and a risk of water damage to the roof or roof leaks. In most cases the use of such decorative roof systems is confined to concrete roofs. There is a need for an improved roof system which addresses such problems.

STATEMENTS OF INVENTION

According to the invention there is provided a roof system comprising a support layer comprising a composite insulated panel of the type having a profiled sheet and a generally flat sheet with an insulating core between the profiled sheet and the flat sheet; and a barrier layer applied to the generally flat sheet of the support layer for reception of an upper decorative layer.

In one embodiment, the barrier layer comprises a root barrier membrane.

In one case the decorative layer comprises a growing medium for plants and the like.

The decorative layer may be arranged to cover only a portion of the top face of the composite insulating panels.

In one embodiment the decorative layer comprises a water receiving layer.

The decorative layer may comprise stones and/or sand and/or gravel.

In one embodiment the decorative layer comprises a drainage, aeration and water storage layer. The drainage, aeration and water storage layer may comprise a top face and a plurality of recessed wells. In one embodiment the recessed wells project downwardly to contact an underlying surface and to space the top face apart from the underlying layer.

In one embodiment the decorative layer comprises a permeable membrane. The permeable membrane may be laid on top of the drainage, aeration and water storage layer. In one case the permeable membrane comprises a geotextile fabric.

In one embodiment the planting medium comprises soil or peat or sand, or any suitable mixture thereof.

In one embodiment the system comprises drainage means.

In one arrangement the panels are connected to supporting external and/or internal walls.

The root barrier layer may be connected to the panels by adhesive or other suitable fixing means.

In one embodiment the barrier layer is connected to the external walls.

The system may comprise a coping, typically of metal for connection to the external walls.

In one embodiment the system comprises a decorative layer retention device to define the perimeter of the decorative layer.

In one embodiment the profiled sheet of the composite insulated panel defines a plurality of channels extending longitudinally along the length of the panel.

The channels may be of generally trapezoidal shape comprising a generally flat base and side walls which extend from and diverge outwardly from the base.

In one case the side walls of the trapezoidal formations are stepped side-walls.

The profiled sheet may have transversely extending reinforcing ribs.

In one embodiment the profiled sheet has a first overlap portion on one side and a second overlap portion on the opposite side, the first overlap portion being substantially free of insulating core, the side edge of the insulating core at the first overlap portion having a first inclined wedge face and the side edge of the insulating core at the second overlap portion having a second inclined wedge face which is oppositely directed to the first inclined wedge face at the first overlap portion, the overlap portions and the wedge faces of the insulating core of adjacent like panels being interengageable on assembly.

The profiled sheet overlap portions may be defined by part trapezoidal portions.

In one embodiment the generally flat or second sheet has a second sheet first overlap portion on one side and a second sheet second overlap portion on the opposite side. The overlap portions may comprise profiled portions of the external sheet.

In one embodiment the second sheet has an outer male projecting part and an inner recess part on one side, and a corresponding outer recess part and projecting inner male part respectively on the opposite side of the panel.

According to the invention there is provided a roof system having a lower layer comprised of one or more composite insulated panels and a separate upper decorative layer.

In one embodiment the roof system comprises an intermediate protective covering layer between the panels and the decorative layer.

In another embodiment the protective covering layer comprises an impermeable roof membrane.

In a further embodiment the protective covering layer further comprises a membrane protection and root barrier.

In one embodiment the decorative layer comprises multiple layers.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be more clearly understood from the following description thereof, given by way of example only, with reference to the accompanying drawings, in which:—

FIG. 1 is a cross-sectional view of a roof system according to the invention;

FIG. 2 is detailed cross-sectional view of the roof system of FIG. 1;

FIG. 3 is an enlarged view of a panel joint detail of the roof system of FIGS. 1 and 2;

FIG. 4 is a cross-sectional view of another roof system according to the invention;

FIG. 5 is detailed cross-sectional view of the roof system of FIG. 4;

FIG. 6 is a perspective view of one sheet of a panel used in the roof system;

FIG. 7 is a plan view of the panel sheet of FIG. 6; and

FIGS. 8(a) to 8(c) are cross-sectional views of various alternative panels of the roof system;

DETAILED DESCRIPTION OF THE DRAWINGS

Referring to the drawings, there is illustrated a roof system 1 comprising a lower layer of panels 2, and a protective barrier layer 3. An upper decorative layer 4, in this case comprising a planting medium suitable for planting and growing vegetation is installed thereon.

Referring to the roof system of FIGS. 1 and 2 the decorative layer 4 is comprised of multiple layers, including a water receiving layer. The decorative layer may be arranged to cover only a portion of the top face of the layer of composite insulating panels. Alternative decorative layers may be installed for example, a layer of stones, sand or gravel or a mixture thereof or a water feature.

The panels 2 comprise a profiled internal sheet 5, a generally flat external sheet 6, and an insulating core 7 therebetween. The sheets are in this case of light gauge steel and the core is of a polyisocyanurate foam material. The panels 2 further comprise corresponding engagement means 8 to enable interengagement of adjacent panels on assembly. The engagement means 8 provides for secure interconnection of the panels 2 providing a mechanically strong roof structure capable of supporting a heavy load.

In this case, the profiled sheet 5 is comprised of a plurality of ridge portions 19 and valley portions 20 and the valley and ridge portions are of generally trapezoidal form.

Referring to FIG. 3, in this case, the external sheet 6 comprises an external male projecting part 21 and an internal recess part 22 on one side for engagement on assembly with a corresponding external recess part 23 and projecting internal male part 24 respectively on the opposite side of the panel. At least a portion of the side edges 25 and 26 of the insulating core 7 between the joint forming portions of the external sheet and internal sheet has an inclined profile and the inclined profiles of the opposite side edges of the insulating core 7 form oppositely directed wedge faces. A side edge of the insulating core of one panel is matched with the opposite side edge of an adjacent panel on assembly.

In use, the panels 2 are supported between an external wall 30 and other supporting walls. When the panels 2 are assembled, the protective layer 3 is laid thereon. The protective layer 3 comprises a roof membrane 10 and a membrane protection and root barrier 11. The roof membrane 10 is installed onto the upwardly facing external sheet 6 of the panels 2 and the membrane protection and root barrier 11 is laid thereon.

When the roof panels 2 are thus covered and protected, the decorative layer 4 is installed. Referring to FIGS. 1 and 2 in this case the decorative layer 4 comprises, from the base upwards, a drainage aeration and water storage layer 12, a further roof barrier layer 13, and a layer of a growing medium 14. Vegetation 15 is planted in the growing medium 14.

The roof membrane layer 10 serves to protect the surface of the panels and to stop any water penetration. The roof membrane 10 is an impermeable membrane for example, of polyvinylchloride (PVC), bitumen or a Thermoplastic PolyOlefin (TPO) type material. Suitable materials include for example, Trocal, Sarna, or Flag. However, it will be appreciated that any suitable material may be used for example a plastics or polymer material.

The membrane protection and root barrier layer 11 is comprised of heat welded PVC, TPO or high density polyethylene and serves to prevent roots from damaging the water proofing layer.

The roof membrane layer 10 and/or the membrane protection and roof barrier layer 11 are applied to the panels 2 on site. In some cases a single root barrier layer is provided on the generally flat upwardly facing sheet of the panels.

The drainage aeration and water storage layer 12 comprises means to control water levels in the planting medium 14. In this case the layer 12 comprises an upper face 17 having a plurality of recessed wells 16. The wells 16 provide water storage and drainage. When the drainage aeration and water storage layer 12 is laid down, the recessed wells 16 project downwardly contact the underlying support and to space the upper face apart from the underlying surface to enable the circulation of air and/or to provide a passage for the drainage of excess water if required.

The roof barrier layer 13 comprises a permeable membrane which serves to prevent soil from the planting layer clogging the drainage aeration and water storage layer. The roof barrier layer 13 is comprised of a geotextile filter fabric, for example.

A suitable planting medium layer 14 is then laid on top of the membrane 13. The planting medium may be comprised of various proportions of soil or sand as required depending on the type of vegetation to be planted.

In the embodiment illustrated, the roof system 1 is installed by connection to the supporting wall 30. The roofing membrane and root barrier are connected to roof panels 2 and to the wall by suitable fixing means, for example by adhesive means or mechanical fixing. The roof membrane and barrier are installed so that they extend over the top face of the panels 2 and upwardly at external walls 30 at the sides of the roof to define a sealed recessed area suitable for planting.

In the embodiment shown, a metal coping 31 is connected to the top of the external wall 30.

A planting medium or soil retention element 33 is installed to define the perimeter of the planting area and to retain the planting medium 14 in that area. A ballast 32, for example of gravel is installed between the soil retention element 33 and the edge of the roof.

Roof sealing is provided by the composite insulated panels 2. Drainage is handled through the drainage layer.

An inner facing such as of plywood or plasterboard 34 may be installed below the roof panels.

Referring to FIGS. 4 and 5 there is illustrated another roof system of the invention in which parts similar to those illustrated in FIGS. 1 and 2 are assigned the same reference numerals. In this case the decorative layer is an extensive garden layer which has minimum maintenance and water requirements. Such systems generally use Alpine plants such as Sedums. The system is of simpler construction than the intensive system described above.

Referring to FIGS. 6 to 8, the preformed composite panels 1 used in the roofing systems of the invention are shown in more detail. The profiled sheet 5 has a plurality of generally trapezoidal formations 30 each having a generally flat base part 31 and a pair of upwardly extending and diverging side walls 32. Stepped back intermediate portions 33 are located between the trapezoidal formations 30. For enhanced structural strength the side walls 32 of the trapezoidal formations are of stepped form. Transversely extending reinforcing ribs 35 are provided in the intermediate portions 33 to again enhance structural performance.

The profiled sheet 5 has a first side overlap portion 40 on one side and a second side overlap portion 41 on the opposite side. The first overlap portion 40 is substantially free of insulating core 7 and the side edge of the insulating core at the first overlap portion has a first inclined wedge face 43. At the second side overlap portion 41 the side edge of the insulating core has a second inclined wedge face 44 which is oppositely directed to the first inclined wedge face 43 so that the wedge faces 43, 44 of adjacent like panels are interengagable on assembly.

The generally flat sheet 6 may have a first overlap portion 50 on one side and a second overlap portion 51 on the opposite side. The first overlap portion 50 comprises an outer male projecting part 52 and an inner recess part 53. The second overlap portion 51 comprises an outer recess part 54 and an inner male projecting part 55 which are interengagable with the outer male projection 52 and the inner recess part 53 of an adjacent like panel, on assembly.

Various alternative constructions of composite panels to suit various requirements used in roofing systems of the invention are illustrated in FIGS. 8(a) to 8(c). In one case (FIG. 8(a)) there is no engagement features formed in the sheet 6.

The roof system of the invention has the advantages of providing a finished insulated roof. The layer of panels defining the lower layer of the roof system are of large span and have a high load carrying capability enabling the installation of a load for example a decorative layer, or a planted medium thereon. It is possible to have a membrane external finish which also acts as a water permeability barrier. The span of the roof depends on the size of the panels used. However, it is noted that the panels have excellent structural strength and may be connected across a wide span without the need for additional/intermediate structural support.

The system of the invention has further advantages including the following:

    • visually attractive with a wide range of possible flower/foliage effects
    • low maintenance with little or no artificial irrigation requirements
    • improved rainwater management, volume and rate of rainwater run off from the roof is reduced dramatically
    • improved building thermal performance, the building is insulated from heat loss in the winter and heat gain in the summer
    • reduction in sound transmission through the roof
    • improvement in air quality by removal of carbon dioxide, release of oxygen and water vapour, deposition of particulate pollutants and absorption of organic volatiles
    • reduction of urban heat island effect
    • provision of habitat for wildlife

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