A ROOF PANEL

PANNEAU DE TOIT

English Abstract

A roof panel (1) for use in forming a low pitch or flat roof comprises a
profiled inner liner or
decking sheet (2), an outer waterproof membrane (3) and a body (4) of
insulation between
the inner liner (2) and outer membrane (3). The membrane liner sheet (3) has a
backing
such as a fleece or scrim to aid adhesion of the membrane (3) to the foam
body. The
membrane (3) comprises a side lap (5) extending sidewardly of at least some of
the marginal
edges of the body (4). The inner liner (2) comprises joint formations for
forming a nested side
lap joint between adjacent panels. The joint formations comprise a first joint
formation (20)
at one edge of the liner (2) and a second joint formation (21) on an opposite
edge of the
panel. The first and second joint formations (20, 21) of adjacent panels are
adapted to
interengage on assembly and are clinched together using a clinching tool (22)
to form a
clinched joint (25). The first joint formation (20) comprises a liner
extension which is shaped
to define a recess. There is an inturned liner leg and a return leg which
define the liner
recess therebetween. The second liner formation (21) comprises a liner
extension which is
shaped to define a projection which is engagable in the recess defined by the
first liner
extension (20). The liner projection is defined by an inturned liner leg which
has a return lip
to reinforce the projection. On assembly of adjacent panels on site, the liner
formations (20),
(21) are inter-engaged ed and clinched together. A foam filler (30) is
provided at the joint.

French Abstract

L'invention concerne un panneau de toit (1) destiné à être utilisé pour former un toit plat ou à faible pente, comprenant un revêtement interne profilé ou une feuille de platelage (2), une membrane externe étanche (3) et un corps (4) d'isolation entre le revêtement interne (2) et la membrane externe (3). La feuille de revêtement de membrane (3) comprend un support tel qu'un molleton ou un canevas pour faciliter l'adhérence de ladite membrane (3) sur un corps de mousse. La membrane (3) comprend un recouvrement latéral(5) s'étendant latéralement au moins à partir des bords limites du corps (4). Le revêtement interne (2) comprend des formations de joint pour former un joint de recouvrement latéral emboîté entre les panneaux adjacents. Les formations de joint comprennent une première formation de joint (20) sur un bord du revêtement (2) et une seconde formation de joint (21) sur un bord opposé du panneau. La première et la seconde formation de joint (20, 21) des panneaux adjacents sont conçues pour être mutuellement solidarisées sur un ensemble et sont rivées ensemble au moyen d'un outil à river (22) pour former un joint rivé (25). La première formation de joint (20) comprend une extension de revêtement qui est mise en forme pour définir un évidement. Une patte de revêtement intérieur et une patte de revêtement repliée définissent entre elles l'évidement de revêtement. La seconde formation de joint(21) comprend une extension de revêtement qui est mise en forme pour définir une saillie qui entre en contact avec l'évidement défini par la première extension de revêtement (20). La saillie de revêtement est définie par une patte de revêtement intérieur qui comprend une lèvre retournée pour renforcer la saillie. Sur l'ensemble de panneaux adjacents sur site, les formations de joint (20, 21) sont mutuellement solidarisées et rivées ensemble. Une charge de mousse (30) est déposée sur le joint.

Claims

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CLAIMS
1. A roof panel for forming a low pitch or a flat roof, the roof panel
comprising:-
an inner liner;
an outer weatherproof membrane;
a body of insulating material between the inner liner and the outer
membrane;
wherein the inner liner comprises joint formations for forming a nested side
lap joint between adjacent panels wherein the joint formations comprise a
first joint formation on one edge of the liner and a second joint formation on

an opposite edge of the liner, the first liner formation of one panel being
adapted for inter-engaging and for clinching with a second liner from of an
adjacent panel; and
wherein the membrane comprises an integral side lap extending sidewardly
of at least some of the marginal edges of the insulation, and the side lap
being
extendable over a joint between adjacent panels to form a sealed joint
between adjacent panels on assembly.
2. The panel as claimed in claim 1 wherein the first liner formation
comprises a
liner extension which is shaped to define a recess.
3. The panel as claimed in claim 2 wherein the liner comprises an inturned
leg
and a return leg which define the liner recess therebetween.

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4. The panel as claimed in any one of claims 1 to 3 wherein the second
joint
formation comprises a liner extension which is shaped to form a liner
projection for locating in the liner recess of an adjacent panel.
5. The panel as claimed in claim 4 wherein the liner comprises an inturned
leg
which defines the liner projection.
6. The panel as claimed in claim 5 wherein the liner projection has a
return lip
to reinforce the projection.
7. The panel as claimed in any one of claims 1 to 6 comprising a fastener
for
fastening the panel to a support.
8. The panel as claimed in claim 7 wherein the fastener is for fastening
the
panel support to a purlin.
9. The panel as claimed in claim 7 or 8 wherein the fastener is a self-
coring
fastener.
10. The panel as claimed in any one of claims 1 to 9 comprising a filler
for
location in the nested side lap joint forming portions of the inner liner.
11. The panel as claimed in claim 10 wherein the filler is of insulation
material.
12. The panel as claimed in any one of claims 1 to 11 wherein the membrane
comprises a unitary sheet of membrane or film.
13. The panel as claimed in any one of claims 1 to 12 wherein the membrane
is
planar.


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14. The panel as claimed in any one of claims 1 to 13 wherein the membrane
is
of uniform structure and thickness.
15. The panel as claimed in any one of claims 1 to 14 wherein the membrane
is
of a flexible plastics material.
16. The panel as claimed in any one of claims 1 to 15 wherein the membrane
is
attached to the insulation body except at a fixing region at one or more of
the
marginal edges.
17. The panel as claimed in claim 16 wherein the side lap of the membrane
is
extended to cover the fixing region on assembly.
18. The panel as claimed in any one of claims 1 to 17 wherein the side lap
extends for bonding to an adjacent panel on assembly.
19. The panel as claimed in claim 18 wherein the side lap is bonded to an
adjacent panel on assembly.
20. The panel as claimed in any one of claims 1 to 19 wherein the body of
insulation comprises an insulation foam.
21. The panel as claimed in claim 20 wherein the insulation foam is factory

formed in situ between the inner liner and the outer layer.
22. The panel as claimed in any one of claims 1 to 21 wherein the inner
liner is of
a metal material.
23. The panel as claimed in any one of claims 1 to 22 wherein the liner is
a
profiled liner.


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24. The panel as claimed in claim 23 wherein the liner comprises nestable
partial
profiles at the side marginal edges thereof.
25. The panel as claimed in claim 24 wherein the joint formations are
provided at
edges of the partial profiles.
26. The panel as claimed in claim 25 wherein the partial profiles are free
of
insulating material prior to assembly.

Description

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"A ROOF PANEL"
Introduction
The invention relates to a roof panel for forming a low pitch or flat roof.
Statements of Invention
According to the invention there is provided a roof panel for forming a low
pitch or a flat
roof, the roof panel comprising:-
an inner liner;
an outer weatherproof membrane;
a body of insulating material between the inner liner and the outer membrane;
wherein the inner liner comprises joint formations for forming a nested side
lap joint
between adjacent panels.
In one embodiment the joint formations are adapted for clinching.
In one case the joint formations comprise a first joint formation on one edge
of the liner
and a second joint formation on an opposite edge of the liner, the first liner
formation of
one panel being adapted for interengaging and for clinching with a second
liner form of
an adjacent panel.
The first liner formation may comprise a liner extension which is shaped to
define a
recess. The second liner formation may comprise a liner extension which is
shaped to
form a liner projection for locating in the liner recess of an adjacent panel.
The liner may comprise an inturned leg and a return leg which define the liner
recess
therebetween.

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The liner may comprise an intumed leg which defines the liner projection. The
liner
projection may have a return lip to reinforce the projection.
In one embodiment the panel comprises a fastener for fastening the panel to a
support
such as a purlin. The fastener may be a self-coring fastener.
In one embodiment the panel comprises a filler for location in the nested side
lap joint
forming portions of the inner liner. The filler may be of insulation material.
In one embodiment the membrane comprises an integral side lap extending
sidewardly of
at least some of the marginal edges of the insulation, and the side lap being
extendable
over the joint between adjacent panels to form a sealed joint between adjacent
panels on
assembly.
The membrane may comprise a unitary sheet of membrane or film. The membrane
may
be substantially planar. The membrane may be of substantially uniform
structure and
thickness.
In one case the membrane is of a flexible plastics material. The membrane may
be pre-
attached to the insulation body except at a fixing region at one or more of
the marginal
edges. The side lap of the membrane may be extended to cover the fixing region
on
assembly.
In one case the body of insulation comprises an insulation foam. The
insulation foam may
be factory formed in situ between the inner liner and the outer layer.
In one embodiment the inner liner is of metal. The liner may be a profiled
liner.
In one embodiment the liner comprises nestable partial profiles at the side
marginal edges
thereof.
The joint formations may be provided at the edge of the partial profiles.

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In one embodiment the partial profiles are free of insulating material prior
to assembly.
In a broad aspect, moreover, the present invention provides a roof panel for
forming a
low pitch or a flat roof, the roof panel comprising: an inner liner; an outer
weatherproof
membrane; a body of insulating material between the inner liner and the outer
membrane; wherein the inner liner comprises joint formations for forming a
nested
side lap joint between adjacent panels wherein the joint formations comprise a
first
joint formation on one edge of the liner and a second joint formation on an
opposite
edge of the liner, the first liner formation of one panel being adapted for
inter-engaging
and for clinching with a second liner from of an adjacent panel; and wherein
the
membrane comprises an integral side lap extending sidewardly of at least some
of the
marginal edges of the insulation, and the side lap being extendable over a
joint between
adjacent panels to form a sealed joint between adjacent panels on assembly.
Brief Description of the Drawings
The invention will be more clearly understood from the following description
thereof
given by way of example only, in which:-
Fig. 1 is a cross sectional view of a roof panel according to the invention;
Fig. 2 is a cross sectional view of a joint between two adjacent roof panels;
Fig. 3 is an enlarged cross sectional view of the joint detail;
Fig. 4 is a cross sectional view of a liner joint detail; and
Fig. 5 is a cross sectional view of a clinched linear joint.

=
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Detailed Description
Referring to the drawings there is illustrated a roof panel 1 according to the
invention
for use in forming a low pitch or flat roof.
The roof panel 1 comprises a profiled inner liner or decking sheet 2, an outer
waterproof membrane 3 and a body 4 of insulation between the inner liner 2 and
outer
membrane 3.
The membrane liner sheet 3 has a backing such as a fleece or scrim to aid
adhesion of
the membrane 3 to the foam body. The membrane 3 may be of a suitable plastics
material such as PVC, TPO and the like. The plastics membrane 3 is provided
with a
suitable backing such as a fleece or fabric.
The membrane 3 comprises a side lap 5 extending sidewardly of at least some of
the
marginal edges of the body 4. The side lap 5 which does not have a fleece or
fabric

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backing is extended over a joint between adjacent panels to form a sealed
joint between
the adjacent panels on assembly.
The membrane 3 is manufactured of a unitary sheet of membrane or film. The
side lap 5
is integral with the membrane 3 pre-bonded to the panel. The membrane 3 is of
substantially uniform structure and thickness throughout and is substantially
planar.
The inner liner 2 which may be of painted galvanised steel is formed with
trapezoidal
portions 9 for improved mechanical and insulation performance.
The insulation may be of any suitable foam material such as a polyurethane
foam, a
polyisocyanurate foam, or a phenolic foam.
The inner liner 2 comprises joint formations a the side marginal edges thereof
for forming
a nested side lap joint between adjacent panels. The joint formations comprise
a first
joint formation 20 at one edge of the liner 2 and a second joint formation 21
on an
opposite edge of the liner. The first and second joint formations 20, 21 of
adjacent panels
are adapted to interengage on assembly as illustrated in Fig. 4 and are
clinched together
using a clinching tool 22 as illustrated in Fig. 5 to form a clinched joint
25.
The first joint formation 20 comprises a liner extension which is shaped to
define a
recess. There is an inturned liner leg 26 and a return leg 27 which define a
liner recess
therebetween.
The second liner formation 21 comprises a liner extension which is shaped to
define a
projection which is engagable in the recess defined by the first liner
extension 20. The
liner projection is defined by an inturned liner leg which has a return lip 28
to reinforce
the projection.
Partial formations, in this case partial trapezoidal portions 7, 8 at the side
marginal edges
of the liner 2 extend laterally of the liner 2 and are free of insulating foam
material when
manufactured for nesting at the joint between adjacent panels. The joint
formations 20,

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21 are provided at the free edges of the partial trapezoidal portions 7, 8. On
assembly,
the partial trapezoidal portions 7, 8 of adjacent panels are overlapped and
interengaged
for enhanced structural strength. On assembly of adjacent panels on site, the
liner
formations 20, 21 are inter-engaged and clinched together. The clinched joint
is then
covered with an insulating foam filler 30 to provide insulation at the joint.
Self coring fasteners 35 are used to fix the panels to an underlying support
36 such as a
purlin or the like.
The membrane 3 is applied to the panel 1 at the site where the panel is
manufactured.
The membrane is bonded to the panel such that an integral membrane side lap 5
extends
sidewardly of at least some of the marginal edges of the panel. The membrane 3
may be
bonded to the panel except at one or more of the marginal edges. The membrane
3 has a
generally smooth finish on the weather (outer) side. On the backing side of
the
membrane which is in contact with the foam there may be a fleece backing to
assist in
ensuring a good bond between the membrane 3 and the foam 4. The overlap
portion 5
does not have a fleece backing.
The membrane has a side lap 5 to which the outer layer is not bonded and this
side lap
may be un-fleeced (no fabric) in this region or the adhesive may be covered
with a
release tape or the like.
A composite panel is produced by laying down liquid foam reactants onto the
liner layer
2. The trapezoidal portions 7, 8 are left free from foam. The liquid foam
reactants may
be poured onto the inner liner 2 and the outer layer 3 applied over the liquid
foam
reactants. The sandwich thus formed is heated in an oven and the liquid foam
reactants
expand to fill the space between the inner liner 2 and the outer membrane
layer 3.
The panel thus formed is cut to a desired length.
In use, a roof is built up by laying a number of the panels side by side on
support purlins.
The joints between adjacent panels are sealed by extending the sidelaps 5 over
the joints

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between adjacent panels and by then applying the side or end laps which may be
heat
sealed, hot air welded, solvent welded or adhesively bonded to the membrane of
an
adjacent panel. The overlapping portion of a side or end lap where provided is
extended
over the free fixing region of the panel and may be similarly sealed to the
outer layer.
The panels are formed so that on assembly and interengagement a generally flat
face to
enable the membrane cover to be extended to completely cover the panel and
joints
between adjacent panels on assembly.
In use, when the panels are overlapped on site primary fixing is carried out
using self
coring fasteners which are applied from above and core down through the foam 4
and
fasten the liner 2 to the supporting structure 36 below. Side-lap clinching of
the nested
joints is then performed, again from above. Finally, the factory cut foam
inserts 30 are
applied and the membrane 5 lap joint is welded.
The roof panels of the invention offer considerable advantages both in terms
of
mechanical performance and thermal efficiency.
As shown in the drawings the invention provides a low pitch or flat roof
system for the
installation and assembly of a waterproof sealed roof.
The invention is not limited to the embodiments hereinbefore described which
may be
varied in detail.
30

Representative Drawing