Note: Descriptions are shown in the official language in which they were submitted.
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"INSULATED MODULAR ROOF SYSTEM"
FIELD OF THE INVENTION
This invention relates to roofing systems, in particular insulated roofing
systems.
BACKGROUND OF THE INVENTION
The background information discussed below is presented to better
illustrate the novelty and usefulness of the present invention. This
background
information is not admitted prior art.
Various roofing systems are known both for flat and sloped roofs to
insulate and waterproof the roof. On flat roofs the most common roofing system
for
waterproofing is a built up laminar structure comprising a plurality of felt
layers with
each layer or series of layers over-laid with a hot bituminous (tar)
composition to
bind the felt to the roof. A layer of gravel tops off the structure. However,
this is a
very labour intensive process and requires onsite machines and equipment (e.g.
to
provide the hot tar).
In recent years, as the advantages of applying insulation on the
exterior as opposed to the interior of the roof deck have become known, the
built up
roof structure has been applied over insulation materials, typically sheets of
insulation material. This created new problems as the insulating materials had
poor
mechanical properties, needed to be fastened to the roof deck, are subject to
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degradation by UV radiation and absorbed moisture. In addition such built up
roof
systems are very labour intensive making them less economical.
Numerous attempts have been made unsuccessfully to solve one or
more of these problems. For example, US 6,418,687 is directed for retro-
fitting
roofs, is field applied and non-modular. In particular, the foamed in place
insulation
described in this patent is designed to be applied over a roof deck or
existing roof
substrate and a rubber membrane is then glued over top of the sprayed
insulation.
Although this addresses some of the problems, a foamed-in place roofing
installation is still very labour intensive to apply and requires spray
foaming
equipment on-site. Furthermore, when one spray-foams a large surface area
there
are often ripples, localized hills and valleys and other imperfections that
are formed
and which translate into corresponding ripples, hills, valleys and
imperfections in the
overlying rubber membrane. These imperfects can then trap water or other
precipitation in localized areas, preventing desired run-off, and ultimately
resulting in
ponding and of such standing water seeping through cracks in the rubber
membrane.
Additionally, even on roofs that are classified as being "flat" it may
desirable to have a slight roof slope for water to run off. A typical minimum
roof
slope is 1% (1/8" per 1'). However, minimum slope for a "flat" roof is often
set by
building code to 2%. However, even for an experienced and skilled spray-foam
application worker, it is difficult to create a flat non-ponding surface using
an on-site,
foamed-in place insulation method. Moreover, it is very difficult, if not
impossible, to
create a slightly sloped roofing surface (from one side of the roof to
another) using
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such an on-site, foamed-in place insulation method; especially in new
construction
wherein there is no pre-existing, pre-sloped roof deck. In such cases, the
system
and method of US 6,418,687 will simply not work.
Therefore, what is needed is a modular roofing system which can be
applied in new buildings, reduces on-site installation time, does not require
a pre-
existing, pre-sloped roof deck, does not require (or reduces the need for) on-
site
spay-foaming equipment, can be installed by unskilled laborers and can provide
for
an overall slope to the resulting roof structure.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the drawings, several aspects of the present invention are
illustrated by way of example, and not by way of limitation, in detail in the
figures,
wherein:
FIG. 1 is a perspective, partial cut-away view of a first embodiment of
the insulated modular roof system;
FIG. 2 is a close-up perspective view of the embodiment of the
insulated modular roof system of Figure 1;
FIG. 3 is a close-up side view of the embodiment of the insulated
modular roof system of Figure 1;
FIG. 4 is a perspective view of another embodiment of the insulated
modular roof system, illustrating a slight slope to the overall roof;
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FIG. 5 is a perspective view of one corner of a modular panel of yet
another embodiment of the insulated modular roof system, the remaining corners
being substantially mirror or flipped images thereof; and
FIGS. 6a and 6b are perspective views of some of the components of
the embodiment of the insulated roof system of Figure 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description is of preferred embodiments by way of
example only and without limitation to the combination of features necessary
for
carrying the invention into effect. Reference is to be had to the Figures in
which
identical reference numbers identify similar components. The drawing figures
are
not necessarily to scale and certain features are shown in schematic or
diagrammatic form in the interest of clarity and conciseness.
A first preferred embodiment of the insulated modular roof system 10
of the present invention is shown in FIGS. 1-3. The system 10 is comprised of
a
plurality of modular panels 20 and a water-proof member 28. The water-proof
member 28 may be provided in sections on each modular panel 20 (e.g. the
embodiment of FIG. 5) or it may be provided separately and placed (or sprayed)
over a plurality of adjacent panels 20 (e.g. the embodiment of FIG. 1). The
system
10 preferably further comprises at least one planar fill, or joint closure,
member 30
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and joint fill material 40 suitable for filling or packing any empty space
between
adjacent modular panels 20 (e.g. the embodiments of FIGS 1-6).
FIG. 1 illustrates four modular panels 20, labelled individually as 20A,
20B, 20C and 20D, and three joint closure members 30, labelled individually as
30A, 30B and 30C. Each modular panel 20 preferably comprises a first planar
member 22, an insulating layer 24 covering substantially all of the first
planar
member 22, a second planar member 26 suitable to cover substantially all of
the
insulating layer 24. As mentioned, in some embodiments of the invention a
water-
proof member 28 portion is provided pre-assembled on each panel (see FIG. 5).
When installed on a building or roof structure RS, the modular panel 20 may be
referred to as a roofing panel 20, the first planar member 22 may be referred
to a
bottom planar member 22 and the second planar member 26 may be referred to as
a top planar member 26; with the insulating layer 24 being generally
sandwiched
between the bottom and top planar members 22, 24.
The use of "roofing", "top," and "bottom" are used herein as respective
references to the orientation of the modular panel 20 on a substantially flat
roofing
structure RS, but there may be uses of the present disclosure where the
modular
panel 20 may be used in different orientations or on other parts of a
building, such
as in a substantially vertical orientation on the side of a building, used as
siding.
The term "up" and "down" may be used with respect to the ground. More
specifically, the term "up" may be used to describe a vector that is normal to
the
ground and away from the ground. More specifically, the term "down" may be
used
to describe a vector that is normal to the ground and pointing toward the
ground. A
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normal is a vector that is perpendicular to a surface such as the ground
surface. In
one embodiment, normal may be defined as a constituent being at +/-90 degrees
with respect to a plane.
When installed on a building or roof structure RS, a plurality of
modular panels 20 will be placed in a generally abutting arrangement so as to
substantially cover the desired surface area of the roof structure RS with the
first
planar members 22; see the arrangement of panels 20A, 20B, 200 and 20D in FIG.
1. Preferably, the first planar member 22 of each modular panel 20 is in
abutting
relation with the first planar member 22 of an adjacent modular panel 20; see
panels 22 labeled 220 and 22D in FIG. 2. The first and second planar members
22,
26, as well as the planar joint closure member(s) 30, may be rigid members
constructed from oriented strand board (OSB), plywood, gypsum board or other
suitably strong material typically used for sheathing in the roof construction
industry.
Advantageously, second planar member 26 provides additional support and
protection to the system 10 as compared to US 6,418,687 where a rubber
membrane is simply applied over top of sprayed insulation.
In one embodiment of a modular panel 20, first planar member 22 is
preferably made up 3/8 inch thick oriented strand board (OSB) sheets,
measuring
approximately 96 inches x 48 inches (8 feet x 4 feet) in length and width. The
insulating layer 24 preferably has slightly smaller length and width
dimensions than
the first planar member 22, preferably measuring approximately 92 inches x 44
inches in length and width. More preferably, the insulating layer 24 is
mounted or
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placed substantially centered on the first planar member 22, thereby providing
a
circumferential space or gap region G around the insulating layer 24,
revealing a
portion of the first planar member 22 and preferably measuring approximately 2
inches wide, as illustrated in FIGS. 2 and 5.
Advantageously, modular panel 20 can be fastened or mounted to the
roof structure RS via one or more fasteners 35 driven, mounted or screwed
through
first planar member 22 at a desired position along said gap region G, as
illustrated
in FIGS 1 ¨ 3. Advantageously said gap region G providing ease of access to an
installer to fasten modular panel 20 to the roof structure RS. Fastener(s) 35
may be
any suitable fastener, e.g. those types of fasteners used in the roofing
industry to
fasten sheathing to a roofing structure RS. For example, fasteners 35 may be
self-
tapping metal screws driven through the gap region G each approximately 12
inches apart from any adjacent fastener. Alternatively, modular panels 20 may
be
mounted to the roofing structure using a glue or construction adhesive.
Preferably, joint fill material 40 is subsequently provided or applied to
the system 10, so as to substantially fill-in all of the gap region G between
adjacent
modular panels, once said panels have been fastened to the roofing structure
RS;
see FIGS. 2 and 3. Advantageously, joint fill material 40 provides further
insulating
and vapour barrier features to the system 10. More advantageously, since only
a
small proportion of the overall system 10 will require application of joint
fill material
40 (the bulk of the insulating properties coming from the insulating layer 24
of the
pre-assembled modular panels 20) onsite labour is significantly reduced as
compared to cases where sprayfoam is applied onsite to the entire roofing
surface.
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Advantageously, a roof or roofing structure RS may quickly be
covered by a plurality of modular panels 20 arranged in abutting relation,
each
panel 20 mounted to the roofing structure via fasteners 35 in the gap region G
and
without the need for hot bituminous (tar) composition to bind the panels 20 to
the
roof. More advantageously, by mounting the modular panels 20 to the roof
structure via the first planar member 22, and by closing the gap space G (and
covering the fasteners 35) with joint fill material 40 the amount of heat loss
through
the system 10 is minimized as compared to cases where a modular panel 20 is
mounted to the roof structure RS via a fastener that penetrates the first
planar
member 22, the insulating layer 24 and the second planar member 24. Instead,
in
the embodiment of FIGS. 1 ¨ 3, any thermal bridging that might otherwise occur
across fastener(s) 35 is significantly reduced or eliminated by having the
fastener(s)
35 driven through the first planar member 22 only.
The second planar member is preferably made up 3/8 inch thick
oriented strand board (OSB) sheets and preferably has slightly smaller length
and
width dimensions than the insulating layer 24 to which it is mounted,
preferably
measuring approximately 90 inches x 42 inches in length and width. More
preferably, the second planar member 26 is mounted or placed substantially
centered on the insulating layer 24, thereby providing a circumferential ledge
or
shoulder region L (of exposed insulating layer 24) there-around, preferably
measuring approximately 1 inch wide, as illustrated in FIGS. 2, 3 and 5.
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Advantageously, planar joint closure member(s) 30 may be mounted or placed
between adjacent modular panels 20 by being positioned on a desired section of
the circumferential ledge region L, prior to being fastened to one or more
modular
panels 20; see FIGS. 2 and 3 showing closure member 30C resting on ledges L of
modular panels 20C and 20D.
The insulating layer 24 and the joint fill material 40 are preferably a
polyurethane foam insulation and, more preferably, is a closed cell foam. In
other
embodiments, the insulating layer 24 and joint fill material 40 may be
comprised of a
foamed synthetic resin made of polystyrene, polyethylene, acrylic resin,
phenol
resin, urea resin, epoxy resin, diallylphthalate resin, urethane resin and the
like.
Advantageously, the use of closed cell foam insulation in the insulating layer
24 and
joint fill material 40 provides an air/vapor barrier inherent in the modular
panel 20
and system 10, so as to efficiently insulate roofs and roof structures RS.
More
advantageously, if the same closed cell foam material is used for both the
insulating
layer 24 and the on-site applied joint fill material 40, the resulting system
10 will
then have a monolithic type insulation formation from one modular panel (e.g.
20A)
to the next panel (e.g. 20B). The invention thereby provides an insulated
modular
modular roofing system 10 that can be quickly installed on a roofing structure
RS,
with minimal on-site labour, with a desired slope S pre-manufactured in each
modular panel 20 and with a continuous (inherent) vapour barrier across the
modular panels 20 on the roofing structure RS. Advantageously, the invention
may
allow for the roofing of a building without the need for additional vapour
control,
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such as separate polyethylene 7,heets that are typically used between a roof
deck or
roof structure and any overlying insulating material.
The thickness of the insulating layer 24 may be determined by the
insulation value that is desired to be achieved by the system 10. For example,
a
3.33 inch thick insulating layer 24 comprised of 2-pound polyurethane foam
insulation, with the first and second planar member 22, 26 comprising 3/8 inch
thick
OSB sheets will typically provide an insulating value of R-20 to the modular
panel
20 and the system 10. A 5.83 inch thick insulating layer 24 comprised of 2-
pound
polyurethane foam insulation, with the first and second planar member 22, 26
comprising 3/8 inch thick OSB sheets will typically provide an insulating
value of R-
35.
During manufacture of the modular panel 20, the insulating layer 24
may be mounted to the first planar member 22 using a suitable glue or
adhesive.
Or the insulating layer 24 may be sprayfoam-applied onto the first planar
member
22 and then such sprayfoamed insulating layer 24 may cut or shaped to the
desired
thickness and slope S. This may be accomplished using a horizontal band saw or
a
horizontal fastwire foam cutter. The CUTLASTm horizontal blade foam slitter is
designed for slicing polyurethane foam into sheets of desired thickness and
would
be suitable for this application.
For example, a partially assembled modular panel 20, with a first
planar member 22 measuring 4 feet x 8 feet may have the insulating layer 24
sprayfoamed thereon to a minimum thickness (e.g. of at least 3.5 inches). This
partially assembled modular panel 20 can then be moved through a OUTLAST"'
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horizontal blade foam slitter which is then set to cut off a thin top section
of the
sprayfoamed insulating layer 24 (e.g. to a height of 3.33 inhes), thereby
providing a
smooth top surface, suitable to receive the second planar member.
Alternatively,
where a roof slope is desired, the CUTLASTm horizontal blade foam slitter can
be
adjusted to cut the insulating layer 24 at a pre-set slope, resulting in a
modular
panel 20 that has that desired slope S with the insulating layer 24 having a
first
thickness (or height) H1 at one end of the panel 20a and a second thickness
(or
height) H2 at an opposing end 20b of the panel (see the embodiment of FIG. 4).
Advantageously, by having a smoothly cut insulating layer 24, and by
utilizing the second planar member 26, the water-proof member 28 on outside or
top surface of the system 10 of modular panels 20 will be substantially
smooth,
thereby reducing or fully eliminating ponding or pooling of trapped water or
other
precipitation in localized areas. Furthermore, if a slight slope S has been
provided
by the modular panels 20, then water or other precipitation will generally be
directed
to quickly run off of the outside or top surface of the system 10.
One or more support members 50 may be provided in the modular
panel 20, preferably between first and second planar member 22, 26, so as to
offer
additional structural support and/or mounting points for the second planar
member
26. Support members 50 may be made of metal, galvanized metal, plastic, wood
or
other suitable material. Preferably, support members 50 are z-girts 50z.
Advantageously, z-girt style support members 50, 50z provide anchor points for
any
fasteners 37 that may be used to mount second planar member 26 adjacent to the
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insulating layer 24. More advantageously, z-girts 50z provide anchor points
for any
fasteners 39 that may be used to mount or place any planar joint closure
member(s)
30 between adjacent modular panels 20.
More preferably, z-girt support members 50z have a first end 51 and a
second end 52, wherein first end 51 is positioned substantially in the gap
space G
adjacent first planar member 22, so that any fasteners 35 used to mount the
modular panel 20 to the roof structure RS may be driven there-through; while
second end 52 is spaced away from the gap space G and positioned substantially
within the insulating layer 24. Advantageously, first end 51 provides
additional
support or backing for fasteners 35, while second end 52 provides a mounting
point
for fasteners 37 or fasteners 39, while also proving a thermal break between
fasteners 35 and 37 / 39 (see FIGS. 2 and 3). In one embodiment (e.g. see.
FIGS.
5 ¨ 6b) an insulating member 60 is provided for each support member 50 between
the first end 51 and planar member 22, to further increase such thermal break
and
prevent thermal bridging between first planar member 22 and second planar
member 26 (see FIGS. 6a ¨ 6b). Insulating member 60 may be comprised of rigid
insulation.
The water-proof membrane 28 is preferably an ethylene-propylene
diene mar (EPDM) rubber membrane, but it may also be made of other suitable
water-proof roofing material such as a membrane made from a variety of
materials
such as styrene-butadiene rubber, acrylonitrile-butadiene rubber, chloroprene
rubber, butadiene rubber, isoprene rubber, butyl rubber, ethylene-propylene
rubber,
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polyisobutylene, styrene-butadiene-styrene block copolymer, styrene-isoprene-
styrene block copolymer, chlorinated polyethylene, polyurea coating, ethylene-
vinyl
acetate copolymer, or SBS modified bitumen roofing membrane.
In the embodiments where the water-proof membrane 28 is provided
.. in sections on each modular panel 20 (e.g. FIG. 5), the length and width
dimensions
of the section 28s of the water-proof member 28 is preferably larger than the
length
and width of the first planar member 22, so as to allow adjacent section 28s
to
overlap once any adjacent modular panels 20 are placed in abutting relation,
or to
overlap with any adjacent roofing flashing. Advantageously, such overlapping
section 28s of water-proof member 28 can be taped and sealed (e.g. with seam
tape and/or a solvent adhesive), after installation of the modular panels 20,
so as to
provide an overall water-proof member 28 to the system 10. For example, an
installer can apply 75 mm (3") wide EPDM seam tape to membrane 28 overlaps
using a solvent adhesive.
Those of ordinary skill in the art will appreciate that various
modifications to the invention as described herein will be possible without
falling
outside the scope of the invention. In the claims, the word "comprising" is
used in
its inclusive sense and does not exclude other elements being present. The
.. indefinite article "a" before a claim feature does not exclude more than
one of the
features being present.
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