Note: Descriptions are shown in the official language in which they were submitted.
INSULATING PANEL RETAINERS
FOR ROOF CONSTRUCTION
For many years, so called flat roofs have
been popular for many applica-tions as they can be
ins-talled at relatively low cost. Such flat roofs
generally consist of a roof deck having a wa-ter
impermeable membrane disposed thereon. In many cases
the water impermeable membrane is comprised of layers
of felt impregnated wi-th bitum~n or tar and adhered
together by means of bituminous adhesive. Oftentimes
the membrane was covered ~ith a layer o gravel. Upon
prolonged exposure to sun and the atmosphere, volatile.
materials would be los-t from -the watex im~ermeable mem
brane resulting in shrinkage, fracture of the membrane
an~ subsequen-t roof leaks.
Significant impxovement~ were made in such
roo~ing as set forth in U.S. Let-te.rs Patent 3,411,256.
A variety of panels have been employed for roof structures
genexally of the flat roof nature and typified by those
disclosed in U.S. Patents 3,02~,172; 3,256,106; 4,067,164;
and 4,045,934. U.S. 3,476,634 discloses a mode of
fastening low density insulating panels in edge -to edge
relationship by means of a connec-tor disposed between
"~.
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the panels which has projections which enter .adjacent
edges of the panels.
Particularly desirable roofing panels are of
generally low density closed cell, generally water
impermeable, synthetic resinous foam; for example,
polystyren~ foam. Generally, such foam is pro-tected
from ultraviolet radiation by means of a layer of
~ravel disposed over the closed cell insulating boards
which usually are of a rectangular configuration. Such
roofs in most insulation applications have been very
successful in that the thermal insulation disposed over
the water impermeable membrane reduces significantly
the maximum -temperature reached by the roof membrane.
Moreover, de-terioration of the roof me~brane from
exposure to sunlight and severe thermal cycling is
significantly reduced. Occasionally such insulation is
applied to roof decks which are not perfectly flat but
which have depressed areas w~ere water may collect. If
such depressed areas are sufficien-tly large, a con
20. siderable force may be exerted by the insulation on the
membrane where the water has collected and tends -to
cause the closed cell thermal insulation to float. In
the event that the insulation is adhered to the rnembrane,
stress is applied -to the membrane. In the event that
2;5 the insulation is no-t adhered to the membrane, and the
insulation floats and if wind is sufficiently strong,
the gravel layer may become displaced and the insula-ting
members displaced relative to one another. In order to
avoid such displacemen-t, one proposal is to apply a
water permeable material to the upp~r surface oF the
insulating elements and bond such:permeable material
there-to to aid in maintaininy the thermally insulating
elements in a desired position relative to one another
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and prevent smaller gravel particles working their way
between or beneath the insulating members, thus
increasing the difficulty of repair. The collection of
water in depressed areas is generally referred to as
"ponding". The phenomenon of ponding is not neces-
sarily present from the time of construction of the
roof but may develop as the building ages, so that what
may have been an initially satisfactory roof may become
through movement of the s-tructure, such as sagging
thereof, an unsatisfac-tory roof. In other instances
depending upon the parapet or like thereof above a roof
structure, or other projections or structures added to
the roof, under high wind conditions localized areas of
the roof may have the gravel layer severely displaced
duriny wind storms. Thus in the event of ponding ln
such areas where what might be considered the gravel
ballast has been removed from one or more of the
insula-ting elemen-ts, a substantial force exists which
tends to displace an unweighted or ballasted insulating
element relative to its neighbors.
It would be desirable if -there were available
an improved thermally insulated roof having a reduced
tendency for thermal insulating elements to be dis-
. placed from one another.
It would also be desirable if there were
available an improved and simple means of preventing
displacement of roof insulatin~ elements rela-tive to
one another.
- It would also be desirable if there were an
improved method for the preparation of a thermally
insulated roof wherein adjacent thermal insula-ting
30,787-F -3-
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elements were not readily displaced relative to one
another .
It would also be desirable if ~here were an
improved means for engaging adjacent xoof insulating
elements to prevent displacement relative to one
another.
These benefits and o~her advantages are
achieved in a roof insulating element retaining device,
said device comprising a first genexally planar member,
a second generally planar me~ber in spaced parallel
relationship to the ir~t planar ~ember; first and
second connecting webs disposed betwe~n and generally
normal to planes of the generally planar members, the
first ~nd seco~d webs bein~ dispos~d generally normal
to each other, said re~aining device being adap~ed ~o
engage at le~st two co~ners of adjacent thermal
insulating eleme~t~ and at least a por~ion of a ~hird
insulating eleme~t.
Advantageously in an alternate e~bodiment,
the retaining device is adapated to engage our
adjacen~ corners o four insulating elements.
Also contemplated wi~hin the ~cope of ~he
pre~nt invention is a ~her~ally~insulat~d roof
employing ~h~ retaining devices of the present
invention.
Also wi~hin ~he ~cope of the present
in~ention is a me~hod of preparing a built-up roof~ ~he
method comprisi~g applyin~ and affi~ing to a roof deck
a water impermeable membrane, dispo~ing on the water
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impermeable membrane a plurality of closed cell water
impermeable thermal insulating members definlng
fissures between adjac~nt members, the improvement
which comprises affixing adjacent thermal insulating
members to each other by means of a retaining device
comprised of first and second spaced apar-t generally
parallel planar elements, the generally planar elements
being maintained in spaced apart fixed relationship by
means of at least two webs, each of the webs being
a~fixed to the planar members and the webs being
disposed generally normal to each other and to the
planar members, said retaining devices engaging at
least -three adjacen-t insulating members.
Further features and advantages o:E the
present invention will become more apparen-t from the
f~llowing specification taken in connection with the
drawing wherein
Figures 1 to 3 provide three views of one
.embodiment of the inventioni
Figure 3A shows a plan view of an alternate
embodiment of the invention;
Figures 4 to 12 depict views of alternate
embodiments of the invention;
Figure 13 is a schematic representation o~ a
flat roof whe.rein adjacent thermal insulating elements
are affixed to each other with a retainer generally
similar to that dep.icted in Figures 3 and 3A; and
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Figure 14 depicts a schematic fractional
representation of a roof in accordance with the present
invention employing a retaining device such as is
depicted in Figures 1-12.
In Figure 1 there is schematically depicted
an isometric view of a re-tainer or clip in accordance
with the invention generally designated by the reference
numeral 20. The retainer 20 comprises a first generally
triangular planar element 21 having a generally
triangular cutout 22 generally centrally disposed
thexein. In parallel fixed spaced relationship to the
planar element 21 is a second generally planar element
23 of generally like configuration to element 21 having
a generally triangular cutout portion 24. The planar
elements 21 and 23 have the general configuration of a
right triangle wherein the corners thereof have been
rounded. A first web 25 is affixed to the planar
elements 21 and 23. The web 25 is disposed generally
normal to the planes of the planar elements 21 and 23.
A second web 26 spaced from the first web 26 is
generally normal to the ~lanes of -the planar elements
21 and 23. The planes of the~webs 25 and 26 are
generally normal to each other. The dotted configura-
tion indicated by the reference numeral 27 1ndicates a
projection of the planes of the webs 25 and 26 to an
lntersection location within a space between the planar
elements 21 and 23.
Figure 2 depicts a plan view of -the retainer
20 of Figure 1 showing the locations of the webs 25 and
26 which are disposed on the sides of -the triangular
elements 23 and 21 generally remote from the h~po-tenuse
of the triangular config~ra-tion.
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Figure 3 is an edge vlew of the retainer 20
showing the relationship of the planar elements 21 and
23 and the webs 25 and 26.
The retainer of Fi$ures 1, 2 and 3 is par-
ticularly suited and adapa-ted for engaging a-t leas-t 2
corners o f an adjacent panel and a side of a third
panel, or alternatively four adjacent corners of four
adjacent panels. With reference to Figure 1, lf -the
dotted configuration 27 is projected to form a cross,
the location o~ the fQur adjacent corners of four
adjacent panels is ob-tained.
In Figure 3A, there is depicted an alternate
embodiment of a retainer 20a comprising a generally
planar cutout triangular element 23a in fi~ed parallel
relationship to a second triangular element of like
configuration separated by a first web 25a and a second
web 26a. The webs 25a and 26a are affixed to the
planar elements 21a and 23a. The webs 25a and 26a are
disposed generally normal to the planes containing
-elements 21a and 23a. The webs 25a and 26a are
disposed generally normal to each other. The dotted
configuration indicated by the reference numeral 27a
indicates intersectlon of the projected plarles of the
webs 25a and 26a.
In Figure 4 there ls depicted an alternate
retainer 40 comprising a first or upper square plate
41, and a second or lower square plate 42 parallel to
plate 41. Plates 41 and 42 are separated by a first
web 43 and a second web 44. The planes of the webs 43
and 44 are generally normal to each other and normal to
planar members 41 and 42.
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In Figure 5 there is depicted an alternate
retainer 50 comprising a first square plate 51 and a
second square plate 52. ~ach of the square plates 51
an~ 52 defines a square opening, the openings being
generally designated by the reference numeral 53. The
plates 51 and 52 are in fixed parallel relationship to
each other and are separated by means of webs 54 and
55. The webs 54 and 55 and the plates 51 and 52 are
arranged in a similar manner to that of the re-tainer 40
of Figure 4.
In Figure 6 there is depicted a retainer 60
havi.ng a first generally planar circular member 61. A
second generally planar circular member 62 is in fixed
parallel co~xial relationship with member 61. The
circular me~bers 61 a~d 62 each define a generally
circular opening 63. The planar elements 61 and 62 are
maintained in fixed spaced relationship by means of a
first web 64 and a second web 65. The webs 64 and 65
are arranyed in a similar manner as are the we~s 43 and
4~ of the retainer 40 of Figure 4.
In Figure 7 there is depicked a retainer 70
having a generally circular plana.r element 71, a second
circular element 72 coaxially arranged with respect to
the element 71. The planar elements 71 and 72 are
~5 separated.by webs 73 and 74 which have plarles generally
normal to each other and normal to the planar elemen-ts
71 and 72.
In Figure 8, there i5 depicted a re-tainer 80
comprising a ~-irst triangular plate 81; a second
triangular plate 82 which is in fixed parallel
relationship with respect to plate 81. The plates 81
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and 82 are separated by webs 83 and 84. Plates 81 and
82 generally have the coniguration of a right triangle.
The webs 83 and 84 are in planes generally normal to
each other and -to the planes of plates 81 and 82. The
plane~ of the webs 83 and 84 intersect within spaces
enclosed by the peripheries of the plates 81 and 82.
In Figure 9 there is depicted a retainer 90
comprising a first and generally L~shaped planar membe~
91 and a second generally L-shaped planar member 92;
the members 91 and 92 being maintained in a fixed
spaced apart relationship with respect to each other by
a first we~ 93 and a second web 94. The webs 93 and 94
extend generally parallel to the legs of the L~shape~
members 91 and 92 and are disposed generally at right
angles to each other and to the planar members 91 and
92.
In Figure lO there is depicted a retainer 100
comprising a first generally planar member 101 and a
second generally planar member 102; each of the members
20 101 and 102 having a generally planar oc-tagonal con-
figuration. The me~bers 101 and 102 are maintained in
a fixed, spaced relationship to each other by means of
webs 103 and 104. The webs 103 and 104 lie in planes
generally normal to each o-ther and normal to -the planar
" 25 elements lOl and 102.
In Figure 11 there is schematically depicted
an exploded isometric view of a retainer 110 comprising
a first or upper generally triangularly-shaped plate
112 and a second or lower generally triangularly-shaped
plate 114. The upper plate 112 is provided wi-th a slot
113 in each of two legs of the plate and extending in a
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direction generally normal or perpendicular to each
other and to the longitudinal direction of the leg in
which each slot is provided. The lower plate 114 is
prov1ded with an ups~anding web 115 and 11~, respec-
tively, on each of two legs of the lower plate andpositioned so that -the webs will extend through their
respective slots 113 when the upper plate is positioned
in a juxtaposed and parallel position with respect to
the lower plate 114. Each of the webs is cut centrally
and longitudinally thereof, as shown at 117, to provide
a pair of tabs 118 and ll9. In practice, the lowe-r
plate of the re-tainer is positioned below the insulating
panels, i.e., be-tween the bottom surface of the panels
and a roof structure, so that panels are pQsition~d in
the same manner as descrlbed with respect to the
retainer of Figures 1 to 3. With the tabs 118 and 119
extended above the upper surfaces of -the insulating
panels, the upper plate 112 is placed in a position
with respect to the lower plate such that the slots 113
are in registry with the tabs of the respective webs.
The upper plate 112 is then positioned such that the
tabs extend through the slots and until th~ plate is in
abutment with the upper surfaces of the insula-ting
panels. The tabs 118 and 119 are then bent ou-twardly,
as shown by the arrows in Figure llA to lock the upper
plate into position to firmly hold the corners and
surfaces o the panels in an adjacent relationship with
respect to each other. The depth of the cut 117 is
sufficient to allow for an adjustment in the spacing of
the plates 112 and 114 wi-th respec-t to each other and
in order to accommodate insulating pla-tes of differen-t
thicknesses.
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Each of the plates 112 and 114 is shown with
a cutout 111. It will be apparent, however, that the
slots 113 may weaken the plates where they are more
easily bent along the longitu~inal axis of the slots.
If that should pose a problem, it is a simple expedient
to provide the upper plate with a smaller cu-tout or
with a plurality of smaller cutouts -to thus strengthen
or provide additional stifflless to the plate.
In order to prevent puncturlng or tearing of
the underlying roofing structure, such as a water
impermeable sheet of a synthetic resinous ma-terial, it
is ~lso preferable to provide the lower surface of the
retainer plate 114 with a rounded surface as illustra-ted
at 114a.
It will be apparent that the adjust~ble
feature illustrated in -the embodiment of Figures 11 and
llA is equally as well applicable to the retainer
emhodiments illustrates in Figures 1 through 10.
A furthex modification of an adjustable
retainer, similar to the retainer illustra-ted in Figures
11 and llA, is shown in Figure 12. There, a generally
triangular retainer 120, shown in an exploded, part-
-sectional view, comprlses an upper plate 122 provided
with a slot 123, and a lower plate 124 provlded wi-th an
upstanding web 125. The web is provided on opposi-te
sides thereof wi-th a plurality of ribs 126 although it
will be obvious that the ribs may be provided on only
one side of the web. The ribs 1~6 are sufficiently
soft or flexible such tha-t the web with the projecting
ribs can be forced through the slo-t 123 and to a dep-th
where the upper plate 122 is securely held against the
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upper surfaces of the insulating panels positioned
between.the upper and lower plates. The ribs 126 wlll
thus lock the upper pl.ate i.n a predetermined position
depending on the thickness of the insulati.ng panels to
be held i~ an edge to edge relationship on the roof
structure. For ease of insertion of the web 125 into
the slot 123, the upper surface of the web is rounded
out as shown at 127.
In the embodiments illustrated in Figures 11
and 12, i-t would be of great convenience if the upstanding
webs can be folded so -that they lie 1at against a
surface of the lower plate in order to facilitate
shipping of a larger number of -the pla-tes in a smaller
container. Folding of the web is readily accomplished
by providing the web with a hinge which allows such
folding during shipment and which can be placed in an
upright position during assembly of the upper pla-te to
the lower pla-te f
In Figure 13 there is depicted a schematic
pa~tially cutaway representation of a roof in accordance
with the present invention generally designated by the
reference numeral 30. The roof 30 comprises a peri.pheral
parapet 31, a roof deck 32, a plurali-ty of thermal
insulating panels 33 and a plurali-ty of half panels
33a. The panels 33 and 33a are arranged with the
parapet 31 on the roof deck 32 in such a man:ner that
joints between panels in -their minor dimension are
staggered. The panels 33 and 33a are maintained in
fixed relationship to each other by means of retainers
20b which have a configuration generally as that
depi.cted in Figures 1-3. A generally water permeabl~
light resistan-t layer 35, such as gravel, is depicted
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above the panels 33 and 33a. A roof structure such as
the roof 30 of Figure 4 is rea~ily pxepared by ins-talling
the panels 33, for example, -the five full panels 33
depicted at ~he left side of Figure 4. At the top of
Figure 4 and adjacent the left hand row of panels 33 is
installed a retainer 20b fixed into position on adjacent
panels 33 and 33a. A panel 33 is then abutted to the
panels 33 of the left hand row and 33a adjacent there-to,
and the corner thereof is slid into the retainer pro-
gressing downwardly to form a second row. The retainer20b is fixed into position ~o engage adjacent panels 33
and ~an additional panel 33 is installed, the procedure
being repeated until the entire roof area is covered.
Due to the light weight of most thermal insulating
panels, such as, for example extruded polystyrene foam
having a density of about two pounds per cubic foot,
panels such as the panel 33a in the second row from the
left are readily installed by raising the adjacent
panels slightly to clear the parapet 31, installing the
panel and lowering the insulation assembly to the roof
deck. Optionally, insulating panels such as panels 33
and 33a may be adhered to the roof deck or simply
joined together by means of retainers 20b without
adhering to the roof deck. In the event that ponding
should occur at some period of time during the life of
the roof, the non-a~lered panels can float; and, not
being adhered to the water permeable membrane, provide
no force which tends to delaminate or place other
undesired stress on the water impermeable membrane.
Figure 14 is a fractional schematic represen-
tation of a cutaway view of an alternate roof construction
in accordance with the present invention generally
designated by the reference numeral 140. The roof
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construction comprises roof deck 141 having disposed
thereon a water impermeable mem~rane 142 and a
plurality of generally rectangular thermal insula-ting
elements designated by the reference numeral 143. The
insulating elements have their corners adjacent to each
other. The adjacent corners are in engagement with a
retainer such as retainer 80 of Figure 8, for example,
with the retainex preventing relative movement be-tween
adjacent panels 1'~3.
Panel retainers in accordance with the
present invention are readily prepared from a variety
of materials. Such materials may be materials such as
stainless steel, galvanized steel, enameled black iron,
pain-ted black iron, tin plate and the like. The choice
of the particular metal and particular finish will
depend upon the environmental conditions. In a
noncorrosive dry atmosphere, low cost sheet steel or
iron is readily employed. For a more corrosive
atmosphere, stain].ess steel is desirable. Webs
separating the planar elements may be welded, spot
welded, brazed, or the like. Usually thermal
insulating panels employed on flat roofs are
suf~iciently deformable that relatively little physical
effoxt is required to force a retaining means into a
desired position, even if riveted construction is
employed on the configuration of web 25 and 26 as
depicted in Figure 3. Alternatively, such re-tainers
may be prepared from synthetic resinous thermoplastic
materials by injection molding, -the choice of the
parkicular material being dependent upon the particular
environmental conditions. Such materials may range
from polycarbonate resins to polystyrene resins,
so~called nylon resins or polyolefin resins, such as
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polyethylene, polypropylene, and the like. The choice
of the particular material being primarily based on the
environment in which it is to be used. Such resins
advantageously may be employed alone or incorporating
fillers such as calcium carbona-te, carbon black, a.nd
the like. If maximum dimensional stability is
required, therm~setting resins such as phenolic resins,
furfuryl alcohol resins and the like may be utilized.
Roofs prepared in accordance with the present invention
employing retainers in accordance with the present
invention exhibit highly desixable stability under
windy and rainy conditions.
When employing cellular synthetic resinous
i.nsulating panels for roof str~ctures.in accordance
with the present invention, in order to facilitate
assembly of the panels and retainers, it is desirable
in many instances to provide retainers which have
rou~ded corners and edges or chamfered edges to thereby
prevent tearing or penetration of the foam panel during
assembly.
As is apparent from the foregoing specifi-
cation, the present invention is susceptible o~ being
embodied wlth various alterations and modifications
which may differ particularly from those that have been
25 described in the preceding specification and description.
For this reason, it is to be appreciated that all of
the foregoing embodiments are intended to be merely
illustrative and is not to be construed or in-terpre-ted
as being restrictive or otherwise limiting of -the
present invention, excepting as it is se-t orth and
deined in the hereto-appended claims.
30,787 F _15w
