Note: Descriptions are shown in the official language in which they were submitted.
CA 02550475 2006-06-20
ITW CASE 15348
ROOFING INSULATION FASTENING SYSTEM
FIELD OF THE INVENTION
The present invention relates generally to roofing
systems, and more particularly to a new and improved system
for securing a plurality of slabs of insulation to the under-
lying roof decking substructure by means of a plurality of
batten strips, batten straps, batten bars, or the like,
wherein the plurality of slabs of insulation are disposed
within a grid-type arrangement comprising a plurality of hor-
izontally or transversely oriented rows of the slabs of insu-
lation and a plurality of vertically or longitudinally ori-
ented columns of the slabs of insulation, wherein alternative
columns of the slabs of insulation are preferably longitudin-
ally offset with respect to the columns of the slabs of insu-
lation which are interposed between the alternative columns
of the slabs of insulation so as to effectively stagger adja-
cent or abutting slabs of insulation with respect to each
other for enhancing wind uplift resistance properties, and
wherein further, the plurality of batten strips, batten bars,
batten straps, or the like, are oriented transversely across
the adjacent, abutting columns of the slabs of insulation so
as to permit each one of the plurality of transversely ori-
ented batten strips, batten straps, batten bars, or the like,
CA 02550475 2006-06-20
to fixedly secure the plurality of slabs of insulation which
are effectively disposed within each transversely oriented
row of the slabs of insulation.
BACKGROUND OF THE INVENTION
Roofing battens, in the form of roofing strips,
roofing straps, roofing bars, or the like, are of course
well-known in the art and industry and are widely used for
securing flexible, thermoplastic roofing sheets or environ
mental membranes to underlying roof decking substructures in
order to protect the same from weather or environmental con-
ditions. The roofing battens may be fabricated from any one
of several different materials, such as, for example, metal,
wood, thermoplastic, or the like, and may be provided with
pre-punched holes or apertures for accommodating mechanical
fasteners, such as, for example, roofing screws, which are
passed through the apertures or holes formed within the
roofing battens so as to in fact secure the roofing battens,
and therefore the flexible, thermoplastic roofing sheets or
environmental membranes, to the underlying roofing substruc-
tures. A thermoplastic or polymeric material having particu-
lar utility for fabricating a roofing batten is disclosed
within United States Patent 4,963,430 which issued to Kish et
al. on October 16, 1990, wherein the polymeric material from
which the roofing batten is fabricated comprises a combina
tion of PET, or polyethylene terephthalate, and a polyolefin,
such as, for example, polypropylene. Still further, other
thermoplastic roofing battens are likewise disclosed within
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United States Patent 5,711,116 which issued to Hasan on Janu-
ary 27, 1998, United States Patent 5,469,671 which issued to
Rathgeber et al. on November 28, 1995, United States Patent
5,349,804 which issued to Van Erden et al. on September 27,
1994, United States Patent 5,319,908 which issued to Van
Erden et al. on June 14, 1994, United States Patent 5,309,685
which issued to Rathgeber et al. on May 10, 1994, United
States Patent 5,242,736 which issued to Van Erden et al. on
September 7, 1993, United States Patent 5,161,342 which is-
sued to Hasan et al. on November 10, 1992, United States Pat-
ent 4,736,562 which issued to Kelly on April 12, 1988, United
States Patent 4,718,211 which issued to Russell et al, on
January 12, 1988, and United States Patent 4,445,306 which
issued to Schauffele on May 1, 1984.
It is noted, however, that despite the fact that
such roofing battens are well-known, and that they have en-
joyed widespread usage in connection with securing such flex-
ible, thermoplastic roofing sheets or environmental membranes
to underlying roof decking substructures in order to protect
the same from weather or environmental conditions, such roof-
ing battens have not been used heretofore in connection with
securing slabs of insulation to the underlying roof decking
substructures. To the contrary, the slabs of insulation have
heretofore been secured to the underlying roof decking sub-
structures by other means. One means or method for securing
the slabs of insulation to the underlying roof decking sub-
structure has comprised the use of suitable adhesives, how-
ever, due, for example, to the variance and severity of wea-
ther and environmental conditions, that is, for example,
large temperature differentials as well as extreme wind con-
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ditions, the various adhesives could not always reliably
maintain the slabs of insulation secured to the underlying
roof decking substructures.
Another means or method of securing the slabs of
insulation to the underlying roof decking substructure com-
prised the use of roofing plates fabricated from steel or an-
other metal, however, as can readily be appreciated, the in-
stallation of the individual roofing plates is very time-con-
suming and tedious to operator personnel. In addition, the
fabrication costs involved in connection with the manufacture
of such metal or steel roofing plates is quite considerable,
as are the freight costs for shipping and transporting such
metal or steel roofing plates due to the considerably large
weight of the metal or steel roofing plates. Still further,
it is noted when the aforenoted flexible, thermoplastic roof-
ing sheets or environmental membranes are to be secured atop
the underlying slabs of insulation in order to protect the
same from weather and other environmental conditions, under-
surface portions of the flexible, thermoplastic roofing
sheets or environmental membranes are adhesively bonded to
the metal or steel plates utilized to secure the slabs of
insulation to the underlying substructures. It has been ex-
perienced, however, that the adhesive, utilized in conjunc-
tion with securing the flexible, thermoplastic roofing sheets
or environmental membranes to the underlying slabs of insula-
tion, does not always adhere well to the metal or steel roof-
ing plates. Accordingly, under, for example, wind uplift con-
ditions, the flexible, thermoplastic roofing sheets or envi-
ronmental membranes tend to pull away or become separated
from the steel or metal roofing plates which then places ad-
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ditional and abnormal stresses upon other regions of the
flexible, thermoplastic roofing sheets or environmental mem-
branes which tends to exacerbate failure of the flexible,
thermoplastic roofing sheets or environmental membranes and
the protection they normally provide for the underlying roof
decking substructures against weather and environmental con-
ditions.
A need therefore exists in the art for a new and
improved roofing insulation fastening system wherein the
slabs of insulation can assuredly be secured to the underly-
ing substructures, wherein the means for assuredly securing
the slabs of insulation to the underlying roof decking sub-
structures does not comprise solely adhesive means which is
unreliable, wherein the means for assuredly securing the
slabs of insulation to the underlying roof decking substruc-
ture does not comprise steel or metal plates which entail a
considerable amount of weight and are labor-intensive and
costly to install, wherein the means for assuredly securing
the slabs of insulation to the underlying roof decking sub-
structures comprise batten strips, batten straps, or batten
bars which are relatively light in weight, are economical to
fabricate, and can easily and rapidly be installed, and
wherein flexible, thermoplastic roofing sheets or environ-
mental membranes can be securely bonded to the batten strips,
batten straps, or batten bars, for assuredly securing the
slabs of insulation to the underlying substructures, such
that the roofing sheets or environmental membranes do not
pull away or prematurely separate from the batten strips,
batten straps, or batten bars so as not to jeopardize the
protective properties of the roofing sheets or environmental
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membranes with respect to the underlying roof decking sub-
structures.
SZJ1~IARY OF THE INVENTION
The foregoing and other objectives are achieved in
accordance with the teachings and principles of the present
invention through the provision of a new and improved system
for securing a plurality of slabs of insulation to the under-
lying roof decking substructure by means of a plurality of
batten strips, batten straps, batten bars, or the like,
wherein the plurality of slabs of insulation are disposed
within a grid-type arrangement comprising a plurality of hor-
izontally or transversely oriented rows of the slabs of insu-
lation and a plurality of vertically or longitudinally ori-
ented columns of the slabs of insulation. Alternative columns
of the slabs of insulation are preferably longitudinally off-
set with respect to the columns of the slabs of insulation
which are interposed between the alternative columns of the
slabs of insulation so as to effectively stagger adjacent or
abutting slabs of insulation with respect to each other for
enhancing wind uplift resistance properties. In addition, the
plurality of batten strips, batten bars, batten straps, or
the like, are oriented transversely across the adjacent,
abutting columns of the slabs of insulation so as to permit
each one of the plurality of transversely oriented batten
strips, batten straps, batten bars, or the like, to fixedly
secure the plurality of slabs of insulation which are effect-
ively disposed within each transversely oriented row of the
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slabs of insulation.
BRIEF DESCRIPTION OF THE DRANINGS
Various other features and attendant advantages of
the present invention will be more fully appreciated from the
following detailed description when considered in connection
with the accompanying drawings in which like reference char-
acters designate like or corresponding parts throughout the
several views, and wherein:
FIGURE 1 is a top plan view partially illustrating
a batten strip which has been constructed in accordance with
the principles and teachings of the present invention, and
which is to be used within a roofing insulation fastening
system for securing a plurality of slabs of insulation to un-
derlying roof decking substructures;
FIGURE 2 is a cross-sectional view of the batten
strip illustrated within FIGURE 1 as taken along the lines
2-2 of FIGURE 1;
FIGURE 3 is a top plan view partially illustrating
a roofing insulation fastening system, constructed in accord-
2o ance with the principles and teachings of the present inven-
tion, wherein a plurality of the slabs of insulation are dis-
posed within a grid-type arrangement comprising a plurality
of horizontally or transversely oriented rows of the slabs of
insulation, and a plurality of vertically or longitudinally
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oriented columns of the slabs of insulation, and wherein fur-
ther, a plurality of batten strips, as illustrated within
FIGURE 1, are oriented transversely across the adjacent,
abutting columns of the slabs of insulation so as to permit
each one of the plurality of transversely oriented batten
strips to fixedly secure the plurality of slabs of insula-
tion, which are effectively disposed within each one of the
transversely oriented rows of the slabs of insulation, to the
underlying roof decking substructure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and more particu-
larly to FIGURE 1 and 2 thereof, a batten strip, batten bar,
batten strap, or the like, which has been constructed in ac-
cordance with the principles and teachings of the present in-
vention, and which is to be used within a roofing insulation
fastening system for securing a plurality of slabs of insula-
tion to underlying roof decking substructures, is disclosed
and is indicated by the reference character 10. The batten
strip 10 can be fabricated, for example, either as a single
ply structure by means of a suitable extrusion process, or as
a tubular member by means of a suitable extrusion process
wherein the tubular member can be subsequently flattened into
a dual-ply structure as illustrated within FIGURE 2. If the
batten strip 10 is manufactured as a tubular member, the fab-
rication process can be similar to that disclosed within any
one of the aforenoted patents which issued to Van Erden et
al. and which are hereby incorporated by reference. The bat-
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ten strip 10 may be fabricated, for example, from polyethyl-
ene terephthalate (PET), although the batten strip 10 may be
fabricated from other materials, such as, for example, poly-
propylene, NYLON~, a suitable polyester, polyvinylchloride
(PVC), or the like. The batten strip 10 may have titanium
dioxide (TiOz) added thereto so as to increase its various
strength properties, and ADMER~ is another additive that may
be incorporated within the polyethylene terephthalate (PET)
so as to reduce the tendency of the batten strip to undergo
or experience splitting as a result of wind uplift forces and
screw fastener torque.
The batten strip 10 has a width dimension W which
is preferably within the range of 0.95-1.03 inches, and has a
thickness dimension T which is preferably within the range of
0.026-0.033 inches. In addition, the batten strip 10 is pre-
ferably provided with a plurality of holes or apertures 12
which are pre-punched into the batten strip 10, and it is
seen that the plurality of holes or apertures 12 are longi-
tudinally spaced from each other, along the longitudinally
extending axis 14 of the batten strip 10, by means of a dis-
tance L which is preferably within the range of 2.97-3.03
inches. In addition, each one of the pre-punched holes or ap-
ertures has a diametrical extent which is preferably within
the range of 0.187-0.197 inches so as to accommodate suitable
mechanical nail or screw fasteners, not shown. Accordingly,
each one of the batten strips 10 may be fixedly secured atop
the slabs of insulation so as to assuredly secure the slabs
of insulation to the underlying roof decking substructure.
Still further, it is to be noted that in addition to the use
of the mechanical nail or screw fasteners, the undersurface
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portion of each one of the batten strips 10 may have a layer
of adhesive disposed thereon.
With reference now being made to FIGURE 3, the use
of a plurality of the aforenoted batten strips 10 in conjunc-
tion with a plurality of slabs of insulation, in order to
fixedly and assuredly secure the plurality of slabs of insu-
lation to an underlying roof decking substructure, will now
be described. FIGURE 3 is a top plan view illustrating the
new and improved roofing insulation fastening system which
has been constructed in accordance with the principles and
teachings of the present invention, which is generally indi-
cated by the reference character 110, and which is illus-
trated as being used in conjunction with a partial section or
region of a roofing structure so as to fixedly and assuredly
secure slabs of insulation onto an underlying roof decking
substructure. More particularly, the underlying roof decking
substructure is adapted to be covered by means of a plurality
of slabs of insulation 112, wherein each one of the slabs of
insulation 112 is approximately eight feet long and four feet
wide, and it is therefore seen and appreciated that each one
of the plurality of slabs of insulation 112 has oppositely
disposed end edge portions 114 and oppositely disposed side
edge portions 116. It is also seen that the oppositely dis-
posed end edge portions 114 of each one of the slabs of insu-
lation 112 are disposed in an end-to-end abutting contact ar-
rangement with the oppositely disposed end edge portions 114
of adjacent slabs of insulation 112, and in a similar manner,
the oppositely disposed side edge portions 116 of each one of
the slabs of insulation 112 are disposed in a side-by-side
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abutting contact arrangement with the oppositely disposed
side edge portions 116 of adjacent slabs of insulation 112.
Continuing further, it is additionally seen that
the plurality of slabs of insulation 112 are disposed within
a grid-type arrangement comprising a plurality of longitudin-
ally spaced, horizontally or transversely oriented rows, as
schematically indicated by means of the loci 118,120,122, and
a plurality of laterally spaced, vertically or longitudinally
oriented columns as schematically indicated by means of the
loci 124,126,128. In connection with this grid-type arrange-
ment of the plurality of slabs of insulation 112, it is noted
further that while the oppositely disposed side edge portions
116,116 of adjacent slabs of insulation 112 disposed within
all of the rows 118,120,122 defining each one of the columns
124,126,128 are respectively located along common, laterally
or transversely spaced, vertically or longitudinally oriented
loci 130,132, the slabs of insulation 112 disposed within,
for example, alternative columns 124 and 128 are longitudin-
ally offset with respect to those slabs of insulation 112
which are disposed within the alternative column 126 which is
effectively interposed between the columns 124,128. In this
manner, the oppositely disposed end edge portions 114,114 of
adjacent slabs of insulation 112 that are disposed within the
columns 124,128 are respectively located along common verti-
tally or longitudinally spaced, horizontally or transversely
oriented loci 134,136, whereas the oppositely disposed end
edge portions 114,114 of adjacent slabs of insulation 112
that are disposed within the column 126 are respectively lo
cated along vertically or longitudinally spaced, horizontally
or transversely oriented loci 138,140 which are vertically or
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longitudinally offset from, or with respect to, the horizon-
tally or transversely oriented loci 134,136. This offset pat-
tern or arrangement of the slabs of insulation 112 serves to
reduce any tendency of the slabs of insulation 112 to become
separated from the underlying roof decking substructure in a
continuously propagated manner if the roofing structure
should be subjected or exposed to extremely high wind uplift
forces .
With reference continuing to be made to FIGURE 3,
it is seen still further that a plurality of the batten
strips 10, as illustrated within FIGURES 1 and 2, are ori-
ented transversely along vertically or longitudinally spac-
ed, horizontally or transversely oriented loci 142,144,146 so
as to continuously extend across or span all of the adjacent,
abutting columns 124,126,128 of the slabs of insulation 112
which completely cover the underlying roof decking substruc-
ture. In this manner, each one of the horizontally or trans-
versely oriented, plurality of batten strips 10 is able to
fixedly secure all of the plurality of slabs of insulation
112, which are respectively located within each one of the
vertically or longitudinally spaced, horizontally or trans-
versely oriented rows 118,120,122 of the grid-type arrange-
ment of the plurality of slabs of insulation 112, onto the
underlying roof decking substructure along a fixation path
which is defined by means of a particular one of the verti-
cally or longitudinally spaced, horizontally or transversely
oriented loci 142,144,146. It is to be particularly noted
that this technique of affixing the plurality of slabs of in-
sulation 112 to the underlying roof decking substructure is
quite different from the conventional or prior art technique
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a
of affixing, for example, the flexible thermoplastic roofing
sheets or environmental membranes to the underlying roof
decking substructure, as has been exemplified by means of
similar batten strips, batten straps, batten bars, or the
like, as has been disclosed within the previously noted pat-
ents which issued to Hasan, Hasan et al., Van $rden et al.,
Rathgeber et al., Kelly, Russell et al., and Schauffele, in
that the batten strips, batten straps, or batten bars of such
patents are normally coaxially aligned with, or disposed im-
mediately adjacent to and parallel with, the longitudinally
extending seamed edge portions defined between adjacent or
mated thermoplastic sheets or environmental membranes. To the
contrary, in accordance with the principles and teachings of
the present invention, the batten strips 10 extend across or
traverse the mating or abutting side edge portions 116,116
defined between adjacent slabs of insulation 112 so as to be
disposed substantially perpendicular to the longitudinally
extending seamed edge portions 116,116 defined between adja-
cent or mated slabs of insulation 112. In addition, the bat-
ten strips 10 are disposed at vertically or longitudinally
spaced positions which are located at an intermediate point
between the oppositely disposed, mated end edge portions 114,
114 of the slabs of insulation 112.
The plurality of batten strips 10 are adapted to be
deposited atop the plurality of slabs of insulation 112, and
fixedly secured to the underlying roof decking substructure,
by means of a standup applicator tool, which is the subject
of copending United States Patent Application which is entit-
led , which was filed on
in the name of Riaz Hasan et al., and which has been assigned
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Serial Number , whereby the standup applicator
tool dispenses the plurality of batten strips 10 along the
vertically or longitudinally spaced, horizontally or trans-
versely oriented loci 142,144,146 and fixedly secures the
same atop the plurality of slabs of insulation 112 by means
of suitable fasteners which are inserted through the pre
punched holes or apertures 12. It may therefore be appreciat-
ed that the application of the plurality of batten strips 10
onto the slabs of insulation 112, and the fixation of the
plurality of batten strips 10 to the underlying roof decking
substructure is substantially faster, easier, and less
fatiguing to operator personnel than the conventional or pri-
or art technique of depositing a plurality of individual in-
sulation plates onto the slabs of insulation and subsequently
securing each one of the individual insulation plates to the
underlying roof decking substructure.
In connection with the dispensing and application
or fixation of the plurality of batten strips 10 onto the
upper surface portions of the plurality of slabs of insula-
tion 112, it has been noted that in addition to the insertion
of the mechanical nail or screw fasteners through the pre-
punched holes or apertures 12 formed within the batten strips
10 so as be fixedly embedded within the underlying roof deck-
ing substructure, the under-surface portion of each one of
the batten strips 10 may also have a layer of adhesive dis-
posed thereon. Still yet further, it is noted that when the
thermoplastic sheets or environmental membranes are to be se-
cured atop the slabs of insulation 112, the batten strips,
similar to those as disclosed within the aforenoted patents
which issued to Hasan, Hasan et al., Van Erden et al., Rath-
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Y v
geber et al., Kelly, Russell et al., and Schauffele, may be
secured both by mechanical fasteners and adhesives. There-
fore, when the adhesives, disposed upon the undersurface por-
tions of the batten strips being used to secure the thermo-
s plastic sheets or environmental membranes atop the slabs of
insulation 112, are adhesively bonded to the upper surface
portions of the batten strips 10 being utilized to fixedly
secure the slabs of insulation 112 to the underlying roof
decking substructure, the fact that the batten strips 10 are
fabricated from a suitable one of the aforenoted thermoplas-
tic materials, the adhesives, disposed upon the undersurface
portions of the batten strips being used to secure the ther-
moplastic sheets or environmental membranes atop the slabs of
insulation 112, will more assuredly bond with, and remain
bonded to, the batten strips 10 than with respect to, or as
compared With, the metal or steel plates conventionally or
heretofore used for fixedly securing slabs of insulation to
the underlying roof decking substructure.
Thus, it may be seen that in accordance with the
principles and teachings of the present invention, there has
been developed and disclosed a new and improved system for
securing a plurality of slabs of insulation to the underly-
ing roof decking substructure by means of a plurality of bat-
ten strips, batten straps, batten bars, or the like, wherein
the plurality of slabs of insulation are disposed within a
grid-type arrangement comprising a plurality of horizontally
or transversely oriented rows of the slabs of insulation and
a plurality of vertically or longitudinally oriented columns
of the slabs of insulation. Alternative columns of the slabs
of insulation are preferably longitudinally offset with re-
CA 02550475 2006-06-20
spect to the columns of the slabs of insulation which are in-
terposed between the alternative columns of the slabs of in-
sulation so as to effectively stagger adjacent or abutting
slabs of insulation with respect to each other for enhancing
wind uplift resistance properties. In addition, the plurality
of batten strips, batten bars, batten straps, or the like,
are oriented transversely across the adjacent, abutting col-
umns of the slabs of insulation so as to permit each one of
the plurality of transversely oriented batten strips, batten
straps, batten bars, or the like, to extend across, span, or
traverse the adjacent slabs of insulation so as to fixedly
secure the plurality of slabs of insulation which are effect-
ively disposed within each transversely oriented row of the
slabs of insulation.
Obviously, many variations and modifications of the
present invention are possible in light of the above teach-
ings. For example, while it has been noted that the batten
strips 10 extend across or traverse the mating or abutting
side edge portions 116,116 defined between adjacent slabs of
insulation 112 so as to be disposed substantially perpendicu-
lar to the longitudinally extending seamed edge portions de-
fined between adjacent or mated slabs of insulation 112, it
is also possible that the batten strips 10 extend across or
traverse the mating or abutting end edge portions 114,114
defined between adjacent slabs of insulation 112 so as to be
disposed substantially perpendicular to the laterally or
transversely extending seamed end edge portions 114,114 de-
fined between adjacent or mated slabs of insulation 112. If
this is the case, then it is also to be noted that the batten
strips 10 will be disposed at horizontally or transversely
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spaced positions which are located at an intermediate point
between the oppositely disposed, mated side edge portions
116,116 of the slabs of insulation 112. It is therefore to be
understood that within the scope of the appended claims, the
present invention may be practiced otherwise than as specif
ically described herein.
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