AU2003288482B2

AU2003288482B2 - A composite roof panel

Info

Publication number: AU2003288482B2
Application number: AU2003288482A
Authority: AU
Inventors: James Carolan
Original assignee: Kingspan Research and Developments Ltd
Current assignee: Kingspan Research and Developments Ltd
Priority date: 2002-12-12
Filing date: 2003-12-12
Publication date: 2009-01-08
Anticipated expiration: 2023-12-12
Also published as: GB0328932D0; GB2396166A; PT1570141E; ATE495324T1; ES2358422T3; IE20030934A1; AU2003288482A1; CN1726329A; GB2396166B; EP1570141A1; DE60335739D1; EP1570141B1; WO2004053252A1; NZ540602A; CN100473792C

Abstract

A composite roof panel for flat or low pitch roofs comprises a generally flat external sheet 2, a profiled internal sheet 3, and an insulating core 4 between the external sheet 2 and internal sheet 3. The external sheet 2 has an external male projecting part 10 and an internal recess part (11, fig 2) on one side for engagement, on assembly, with a corresponding external recess part 12 and projecting inner male part 13 respectively on the opposite side of the panel. At least a portion of the side edges 21, 22 of the insulating core 4 between the joint forming portions of the external sheet and internal lining sheet has an inclined wedge profile. The inclined wedge profiles of the side edges 21, 22 of the insulating core 4 form oppositely directed wedge faces. A side edge 22 of the insulating core 4 of one panel (20A, fig 3A) is matched with the opposite side edge 21 of an adjacent panel (20B, fig 3A). On assembly, a first overlap portion (31, fig 3B) of the panel receives a second overlap portion (32, fig 3B) of the adjacent panel. A joint reinforcing plate (40, fig 3C) has a downwardly extending locator defined by a projection (41, fig 3C) which is located in a gap (35) at the joint to ensure that the reinforcing plate (40) is accurately positioned relative to the joint. The plate (40) has holes (42, 43, fig 3C) to receive joint fasteners (44,45, fig 4).

Description

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00 00 00 "A composite roof panel" Introduction The invention relates to a composite roof panel comprising an external sheet, an internal liner sheet ard an insulating core between the external sheet and the liner sheet.

Composite roof panels of this type are known and are widely used for pitched roofs.

Flat roofs or those having a small pitch angle of less than about 2' are generally covered by metal sheets extending between and fixed to purlins and/or supports. An insulation material such as sheets of insulating foam are then laid on site on the metal sheets and the insulating material is covered with a weatherproof membrane. Such a system is generally inconvenient 00 because of the difficulties in performing such work on site. Such systems are slow to build. In addition, there is a risk of damage to the membrane by 0 Z installers. Further, known systems are generally not rigid or stiff and the load Mc, bearing capacity is very limited.

This invention is directed to providing an improved flat roof panel and panel 00 assembly which will address at least some of these problems.

00 00 The discussion of documents, acts, materials, devices, articles and the like is 0 10 included in this specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all of these matters formed part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed before the priority date of each claim of this application.

Throughout the description and claims of this specification, the word "comprise" and variations of the word, such as "comprising" and "comprises", is not intended to exclude other additives, components, integers or steps.

Summary of the Invention According to the invention there is provided a composite roof panel for a flat or substantially flat roof comprising: a substantially flat external sheet; a profiled internal sheet having a plurality of substantially trapezoidal portions; and an insulating core between the external sheet and the internal sheet; the panel having a first overlap portion extending along one side and a second overlap portion extending along an opposite side; 00 the internal sheet having an internal sheet first overlap portion 0 Z on one side and an internal sheet second overlap portion on the Cc opposite side, the first overlap portion of the internal sheet being substantially free of insulating core; 00 the side edge of the insulating core at the first overlap portion 00 having a single first wedge face that is inclined outwardly from 00 the internal sheet first overlap portion and extends to the O 10 external sheet and the side edge of the insulating core at the C' second overlap portion having a single second wedge face which is oppositely directed to the first wedge face and which is inclined inwardly from the internal sheet second overlap portion to the external sheet; the internal sheet overlap portions of adjacent like panels being interengagable on assembly and the first and second wedge faces of the insulating core of adjacent like panels being interchangeable on assembly for substantially the thickness of the panels.

In one embodiment one of the wedge faces of the insulating core extends at an angle of from 70' to 800 and the other of the wedge faces of the insulating core extends at a corresponding angle of from 1100 to 1000. Preferably, one of the wedge faces of the insulating core extends at an angle of approximately 750 and the other of the wedge faces of the insulating core extends at a corresponding angle of approximately 1050.

The substantially trapezoidal portions may have stepped side walls.

In one embodiment the internal sheet overlap portions are defined by part trapezoidal portions.

WO 2004/053252 PCT/IE2003/000168 -3- Preferably, the trapezoidal portions have a depth of at least 90mm, most preferably about 110mm.

In one embodiment the external sheet has an external sheet first overlap portion on one side and an external sheet second overlap portion on the opposite side. The extemrnal sheet may have 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.

On assembly, the outermost edges of adjacent panels may be spaced-apart at a joint therebetween to define a gap.

In one embodiment the gap defines a locator for an external reinforcing plate extending between the external sheets of adjacent panels, on assembly.

The invention also provides an insulated panel assembly comprising a plurality of the panels of the invention.

In one embodiment the assembly comprises a reinforcing plate for extending across a joint between adjacent panels.

In a preferred embodiment the reinforcing plate has a locator which may be for engagement in a gap between external sheets of adjacent panels.

Preferably the reinforcing plate has a hole to receive a joint fastener.

The invention also provides a reinforcing plate for an insulated panel assembly as described and illustrated.

WO 2004/053252 PCT/IE2003/000168 -4- 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 perspective view of a roof panel according to the invention; Fig. 2 is a cross-sectional view of the panel of Fig. 1; Fig. 3a is a cross sectional view of a portion of two adjacent panels according to the invention separated; Fig. 3b is a cross-sectional view of the panels jointed together; Fig. 3c is a cross-sectional view of adjacent panels with a reinforcing plate in place; Fig. 4 is a cross sectional view of adjacent panels with fixings in place; Fig. 5 is a cross sectional view of an external sheet of the panel; Fig. 6 is a cross sectional view of a joint detail between external sheets of adjacent panels; Fig. 7 is a cross sectional view of an internal sheet of the panel; and Fig. 8 is a view on A-A in Fig. 7.

WO 2004/053252 PCT/IE2003/000168 Detailed Description of the Drawings Referring to the drawings, there is illustrated an insulated panel according to the invention comprising a generally flat external sheet 2, a profiled internal decking sheet 3, and an insulating core 4 between the external sheet 2 and internal sheet 3. The sheets 2 and 3 are typically of steel material and the core 4 is of polyurethane or polyisocyanurate foam material which fills the space between the sheets 2, 3. The panel 1 is used for a flat or low pitch (less than 20) roofing system.

The outer flat steel sheet 2 may have a prebonded weather membrane such as a plastics membrane, for example of polyvinylchloride. In this case the PVC membrane is heat sealed at the panel joint when assembled on site. The outer sheet 2 may have a prebonded bitchumen type membrane to which a further bitchumen type membrane may be applied on site. The outer sheet 2 may also not have a prebonded weather membrane. In this case, a weather membrane such as a PVC membrane may be applied on site.

The external sheet 2 and internal sheet 3 have profiled joint-forming portions for connecting adjacent panels, on assembly as illustrated. In this case the external sheet 2 has an external male projecting part 10 and an internal recess part 11 on one side for engagement, on assembly, with a corresponding external recess part 12 and projecting inner male part 13 respectively on the opposite side of the panel.

At least a portion of the side edges 21, 22 of the insulating core 4 between the joint forming portions of the external sheet and the internal lining sheet has an inclined profile and the inclined profiles of the side edges 21, 22 of the insulating core 4 form oppositely directed wedge faces. A side edge 22 of the insulating core 4 of one panel is matched with the opposite side edge 21 of an adjacent panel 20B, on assembly.

WO 2004/053252 PCT/IE2003/000168 -6- For optimum performance one wedge face of the insulating core extends at an angle of from 700 to 800, ideally about 750 and the opposite wedge face extends at a corresponding angle of from 1100 to 1000, ideally about 1050.

The internal decking sheet 3 has a plurality of generally trapezoidal portions. For improved performance the side walls of the trapezoidal portions are stepped. The bases of the trapezoidal sections also have transversely extending reinforcing ribs For optimum performance the depth of the trapezoidal portions is at least preferably about 11lmm. The thickness of the insulating foam between the portion of the internal sheet between the trapezoidal portions and the external sheet is generally at least 50mm and may be at least The inner sheet 3 comprises a first overlap portion 31 on one side which extends laterally of the external sheet 2 and is free of insulation. The inner sheet 3 also has a second overlap portion 32 on the opposite side of the panel. On assembly, the first overlap portion 31 of the panel receives the second overlap portion 32 of the adjacent panel.

It will be noted that on assembly of adjacent panels a gap 35 is defined between the outermost edges of the external sheet 2. A joint reinforcing plate 40 has a downwardly extending locator defined by a projection 41 which is located in the gap to ensure that the reinforcing plate 40 is accurately positioned relative to the joint.

The plate 40 has two holes 42, 43 to receive joint fasteners 44, 45. Thus the reinforcing plate 40 ensures that the fasteners 44, 45 are correctly located at the joint which is important in ensuring the integrity of the fastened joint, especially in relation to the fastener 44 which may extend through several plys of the joint forming portion of both the external and internal sheets 2, 3. The fasteners 44, 45 have low profile heads to facilitate application of a weather seal plastics (such as PVC) strip 46 over the fastener plates 40 and the joint.

00 O It will be appreciated that, if desired, one or more factory applied and/or site applied seals may be provided at the joint between adjacent panels. For Z example, a seal may be located in the gap 35. One or both of the side edges of the insulating core may be covered with an insulating tape.

Embodiments of the invention provide an insulating roof panel which 00 facilitates a high quality joint between adjacent panels. The joint ensures a 00 high level of insulation and fire performance but also has a high mechanical 00 N' strength by virtue of the wedge faces of the insulating core at the joint and the 10 overlap. Because of these features the panel may be used in wider spans than has heretofore been possible. The panels are easily handled and can be built up to achieve a 5 to 6 metre double span. The reinforcing plate and associated fasteners also assist in optimising the strength of the assembled panels.

Thus, embodiments of the invention may provide an insulated roof panel with highly efficient installation, insulation, fire performance and mechanical performance.

It will be appreciated that the panels may be provided with opposite side edges or two different panels with a similar profile on both side edges may be provided.

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

Claims

1. A composite roof panel for a flat or substantially flat roof comprising: a substantially flat external sheet; 00 a profiled internal sheet having a plurality of substantially 00 trapezoidal portions; and 00 0 10 an insulating core between the external sheet and the internal C sheet; the panel having a first overlap portion extending along one side and a second overlap portion extending along an opposite side; the internal sheet having an internal sheet first overlap portion on one side and an internal sheet second overlap portion on the opposite side, the first overlap portion of the internal sheet being substantially free of insulating core; the side edge of the insulating core at the first overlap portion having a single first wedge face that is inclined outwardly from the internal sheet first overlap portion and extends to the external sheet and the side edge of the insulating core at the second overlap portion having a single second wedge face which is oppositely directed to the first wedge face and which is inclined inwardly from the internal sheet second overlap portion to the external sheet; the internal sheet overlap portions of adjacent like panels being interengagable on assembly and the first and second wedge faces of the insulating core of adjacent like panels being interchangeable on assembly for substantially the thickness of the panels. 00

2. A roof panel as claimed in claim 1 wherein one of the wedge faces of the insulating core subtends an angle of from 70' to 800 with the external 0 Z sheet and the other of the wedge faces of the insulating core subtends a CC corresponding angle of from 1100 to 1000 with the external sheet.

3. A roof panel as claimed in claim 2 wherein one of the wedge faces of the 00 insulating core subtends an angle of approximately 750 with the 00 external sheet, and the other of the wedge faces of the insulating core 00 C subtends a corresponding angle of approximately 105' with the external 0 10 sheet.

4. A roof panel as claimed in claim 4 wherein the substantially trapezoidal portions have stepped side walls.

5. A roof panel as claimed in any preceding claim wherein the internal sheet overlap portions are defined by part trapezoidal portions.

6. A roof panel as claimed in any preceding claim wherein the trapezoidal portions have a depth of at least

7. A roof panel as claimed in claim 6 wherein the trapezoidal portions have a depth of about 110mm.

8. A roof panel as claimed in any preceding claim wherein the external sheet has an external sheet first overlap portion on one side and an external sheet second overlap portion on the opposite side.

9. A roof panel as claimed in claim 8 wherein the external 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.

A roof panel as claimed in any preceding claim wherein, on assembly, the side edges of the external sheets of adjacent panels are spaced- apart at a joint therebetween to define a gap. 00 c-I

11. A roof panel as claimed in claim 10 wherein the gap defines a locator for 0 z an external reinforcing plate extending between the external sheets of adjacent panels, on assembly.

12. A roof panel as claimed in any preceding claim wherein the external 00 sheet is coated on the weather side with a weather membrane. 00 00 CI

13. A roof panel as claimed in claim 12 wherein the membrane is of a S 10 plastics material.

14. A roof panel as claimed in claim 12 or 13 wherein the membrane is of polyvinylchloride.

15. A roof panel as claimed in any preceding claim wherein the external sheet is of sheet steel.

16. A roof panel as claimed in any preceding claim wherein the internal sheet is of sheet steel.

17. A roof panel substantially as hereinbefore described with reference to the accompanying drawings.

18. A roof panel assembly comprising a plurality of the panels as claimed in any of claims 1 to 17.

19. An assembly as claimed in claim 18 including a reinforcing plate for extending across a joint between adjacent panels.

20. An assembly as claimed in claim 19 wherein the reinforcing plate has a locator.

21. An assembly as claimed in claim 20 wherein the locator is for engagement in a gap between external sheets of adjacent panels. 00

22. An assembly as claimed in any of claims 19 to 21 wherein the reinforcing plate has a hole to receive a joint fastener. O C

23. A roof panel assembly substantially as hereinbefore described with reference to the accompanying drawings 00 00 00 (-N