Roof Construction

Abstract

A roof construction comprising a substrate, a plurality of bracket members, a plurality of sliding clips and a plurality of interlocking panels. The plurality of bracket members is coupled to the substrate. The plurality of sliding clips is coupled to the plurality of bracket members. The plurality of interlocking panels is coupled to the sliding clips.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority from U.S. Pat. App. Ser. No. 62/567,360 entitled “Roof Construction” filed Oct. 3, 2017, the entire disclosure of which is hereby incorporated by reference in its entirety.

This application is related to, but does not claim priority from, U.S. Pat. No. 9,151,052 entitled “Insulation System for Buildings” issued Oct. 6, 2015, as well as to the references cited therein, and the continuations thereof, one of which remains pending, namely, U.S. patent application Ser. No. 15/415,068 having the same title, and filed Jan. 25, 2017, the entire disclosure of each is hereby incorporated by reference in its entirety.

BACKGROUND OF THE DISCLOSURE

1. Field of the Disclosure

The disclosure relates in general to roof construction, and more particularly, to a roof construction that utilizes bracket members in cooperation with interlocking panels and sliding clips coupling the interlocking panels together.

2. Background Art

The use of a roofing system comprising interlocking panels and sliding clips is well known in the art. One such roofing system is manufactured and sold by BEMO USA of Mesa, Ariz. (www.bemousa.com). Such a roofing system, as will be described is generally configured to be coupled to a roof substrate.

While such a configuration is well known, there exists a need for improvement. That is, it would be desirable to provide support and insulative capabilities to the roofing system between the substrate and the interlocking panels. Such a configuration improves the performance of the roofing system, while providing strength and durability that is not negatively impacted.

SUMMARY OF THE DISCLOSURE

The disclosure is directed to a roof construction comprising a substrate, a plurality of bracket members, a plurality of sliding clips and a plurality of interlocking panels. The plurality of bracket members is coupled to the substrate. The plurality of sliding clips is coupled to the plurality of bracket members. The plurality of interlocking panels is coupled to the sliding clips.

In some configurations, the substrate comprises a one of a flat and an oblique surface.

In some configurations, at least one of the bracket members includes a first end wall and a second end wall with a body wall spanning therebetween. The first end wall is coupled to the substrate. A plurality of sliding clips are coupled to the second end wall.

In some configurations, the first end wall and the second end wall are parallel to each other with the body wall being perpendicular to each of the first and second end walls.

In some configurations, the interlocking panels comprise metal panels having a cross-sectional configuration.

In some configurations, insulation is positioned between the substrate and the plurality of interlocking panels.

In some configurations, the first end wall further includes a first reinforcement channel, with a first end wall strip slidably positioned therein. The second end wall further includes a second reinforcement channel, with a second end wall strip slidably positioned therein.

In some configurations, the first reinforcement strip and the second reinforcement strip each comprise a metal member.

In some configurations, the sliding clips comprise a metal member.

In some configurations, at least a pair of bracket members are positioned in an abutting side by side configuration. At least one of the plurality of sliding clips is coupled to each of the pair of bracket members that are positioned in a abutting side by side configuration.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will now be described with reference to the drawings wherein:

FIG. 1 of the drawings is an existing roofing system applied to a roof of a building;

FIG. 2 of the drawings is a sliding clip of the type utilized with the roofing system of FIG. 1;

FIG. 3 of the drawings is a prior art illustration of the installation of the roofing system of FIG. 1;

FIG. 4 of the drawings is a perspective view of a bracket member for use with the roof construction of the present disclosure;

FIG. 5 of the drawings is a cross-sectional view of the bracket member shown in FIG. 4;

FIG. 6 of the drawings is a cross-sectional view of an installation of the roof construction of the present disclosure; and

FIG. 7 of the drawings is a cross-sectional view of an alternate construction of the roof construction of the present disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

While this disclosure is susceptible of embodiment in many different forms, there is shown in the drawings and described herein in detail a specific embodiment(s) with the understanding that the present disclosure is to be considered as an exemplification and is not intended to be limited to the embodiment(s) illustrated.

It will be understood that like or analogous elements and/or components, referred to herein, may be identified throughout the drawings by like reference characters. In addition, it will be understood that the drawings are merely schematic representations of the invention, and some of the components may have been distorted from actual scale for purposes of pictorial clarity.

Referring now to the drawings and in particular to FIGS. 1 through 3, a prior art roofing system is shown at 100. The roofing system includes interlocking panels 102 that are positioned onto a substrate 106. The interlocking panels are fastened/coupled to the substrate 106 through sliding clips 104. The sliding clips allow for relative slidable movement between the clip and the interlocking panels to allow for thermal expansion and the like. Relative rotative movement is generally precluded. In the configuration shown in FIG. 3, the substrate is generally horizontal or flat. In the configuration shown in FIG. 1, the roofing system is installed in an inclined manner, that is, at an oblique angle to the ground or to the floors of the building. It will be understood that the roofing system can be installed at any angle and that the particular configuration of the roofing system is not to be limited to any particular angular position. Additionally, it will be understood that while the interlocking panels are shown as being substantially planar members having upstanding sides (and reinforcing ribs therealong), the panels may be arcuate or otherwise non-planar in other configurations.

The present disclosure incorporates the roofing system and combines the same with the bracket system that is described, claimed and incorporated by reference in the patent and pending application disclosed above, namely U.S. Pat. No. 9,151,052 and the application Ser. No. 15/415,068.

In greater detail, Bracket member 14 (also known in the industry as a “girt”) is shown in FIGS. 4 and 5 as cooperating with the insert rigidity members 16. The bracket member itself comprises a polymer member, or a composite member that includes body wall 202, first end wall 204 and second end wall 206. In the embodiment shown, the first end wall 204 is generally perpendicular to the body wall 202 and the end wall 206 is likewise perpendicular to the body wall 202. It is contemplated that the bracket comprises an elongated member which is of a generally uniform cross-sectional shape, with variations that may be positioned along the length thereof.

Typically, such bracket members may be provided in any number of standard sizes that may be from only a couple of feet long to spans that are forty to fifty feet long. It is most preferred that the bracket members comprise a pultruded profile that includes both stranded members and woven members within a resin matrix. It will be understood that the shape can be formed through one or more pultrusion dies to achieve the final desired configuration. It is contemplated that a single resin system may be utilized, or that multiple resin systems may be utilized. Of course, the particular configuration and application may dictate changes to the relative thicknesses and dimensions of the different components. Among other fibers, it is contemplated that the fibers may comprise glass fibers (fiberglass), carbon fibers, cellulose fibers, nylon fibers, aramid fibers, and other such reinforcing fibers.

The bracket members provide a thermal break. As used herein, the term “thermal break” refers to a break in like materials wherein the material disposed between like materials is comprised of a material having low thermal conductivity such as a polymeric material having a high R-value as further described below. R-values are measurements of the thermal resistance of different materials. R-values are well known by those skilled in the art of the construction and insulation industries. A high R-value indicates a highly insulative material, such as an R-value of R.2 per inch and higher. Conductive materials have a very low R-value, such as steel which exhibits a negligible or nearly non-existent R-value. In the configuration of the present disclosure, there are no like materials in contact with one another, nor is there any metal to metal contact creating a pathway for heat to transfer from the exterior to the interior and vice versa.

It is also contemplated that the bracket members may comprise anticorrosive polymeric materials that exhibit high insulative qualities or rather, demonstrate high R-value properties such as an R-value in the range of about R.2 to about R8 per inch. Polymeric materials suitable for the present disclosure include thermoplastics or thermoset resin materials including for example: acrylonitrile-butadiene-styrene (ABS) copolymers, vinylesters epoxies, phenolic resins, polyvinyl chlorides (PVC), polyesters, polyurethanes, polyphenylsufone resin, polyarylsulfones, polyphthalimide, polyamides, aliphatic polyketones, acrylics, polyxylenes, polypropylenes, polycarbonates, polyphthalam ides, polystyrenes, polyphenylsulfones, polyethersulfones, polyfluorocarbons, bio-resins and blends thereof. Other such thermoplastics and thermoplastic resins suitable for the present disclosure are known in the art which demonstrate high R-values and are thereby heat resistant as well as anticorrosive. Thermoplastics of the present disclosure are also contemplated using a recyclable polymer or are made of a polymeric material which is partially comprised of a renewable resource such as vegetable oil or the like in its composition when an eco-friendly or “green” bracket member is desired. The polymeric material of the present disclosure can also be reinforced with a reinforcing fiber as detailed below. Bracket members composed of the materials discussed above form a thermal break between exterior panels and building substrates in an effort to control the temperature within a building structure by reducing or eliminating thermal conductivity from the exterior panel to the building substrate and vice versa. In assembly, the R-value of an exterior wall panel system of the present disclosure can typically exhibit a R-value from about R.2 to about R30 per inch depending on the thickness of the overall system, the insulation materials used and the composition of the bracket members. Further, microspheres, such as polymeric or glass nanospheres, can be added to the makeup of the brackets to provide further insulative properties and increased R-value expression.

There are several different types of measurements that relate to a materials ability to insulate, resist, transmit or conduct heat across a material. Particularly, a material's K-value relates to a specific material's thermal conductivity, a material's C-value correlates to the material's thermal conductance, a material's R-value relates to a material's thermal resistance, and a U-value relates to the thermal transmittance of an overall system. In designing a wall, roof or deck bracket and panel system providing adequate insulative properties for a building structure, materials with low K-values and C-values are desired while materials with high R-values are desired. When this set of conditions is met, the overall thermal transmittance, or U-value, of the system is low. Thus, the lower the U-value, the lower the rate heat thermally bridges from one material to another. A building structure having a well insulated system will have a much lower U-value than an uninsulated or poorly insulated system exhibiting high thermal transmittance.

Regarding the R-value of the bracket members of the present disclosure, a relatively high R-value is desired to ensure adequate insulation of a building structure from outside elements by making a bracket that creates a thermal break in a wall panel system. A range of R-values for the polymeric materials used to construct the bracket members described above would be a range of about R.2 to about R8 per inch in order to create a thermal break that effectively reduces or eliminates thermal bridging. The thermal conductivity, or K-value, is the reciprocal of the material's R-value, such that for a polymeric material exhibiting an R-value of about R.2 to R8 per inch, the correlating K-value for that material would be from about K5 to about K0.125 per inch. Thus, in comparison to present day metal brackets used in other bracket and panel systems made of iron or steel, a polymeric bracket member of the present disclosure will exhibit a K-value of approximately about K.5 to about K0.125 per inch at a given set of conditions as compared to a bracket made from a metallic material such as iron or steel which would have an approximate K-value as high as K32 to K60 per inch at the same conditions. This is because metallic materials, such as iron and steel, have low or negligible R-values and are well known conductors of heat. Steel is known to have an R-value of about 0.003 R per inch. Thus, for example, a steel bracket compared to a polymeric bracket of the present disclosure having an R-value of R.55 would be 183 times more thermally conductive.

The body wall 202 includes top surface 210 and bottom surface 212 which extend from first end 214 to second end 216, upper rib 218 and lower rib 220. The upper rib extends outwardly from the top surface 210 between the first and second ends, bisecting the top surface into a top first end portion 222 and a top second end portion 224. The upper rib 218 preferably extends substantially perpendicularly to the top surface 210, and, includes first side 236, second side 238 and tip region 240 spanning therebetween. The first side 236 and the second side 238 are generally parallel to each other for at least a portion of the length. The size of the upper rib 218 is that it substantially matches that of the longitudinal slots 120 of the insulation panel 12, while being slightly oversized in a number of the dimensions, if not in virtually all dimensions or all dimensions. That is, preferably, the upper rib 218 has the same shape as the longitudinal slots 120 except that it is larger dimensionally than the longitudinal slots by an amount that allows for at least elastic deformation of the longitudinal slot 120 upon insertion of the upper rib 218 therein.

The lower rib 220 preferably extends substantially perpendicularly to the bottom surface 212 of the body wall 202, and, includes first side 230, second side 232 and tip region 234. The lower rib 220 is preferably positioned on the opposite side of the upper rib 218, and has the same dimensions as the upper rib. As with the upper rib, the lower rib bisects the bottom surface 212 into a bottom first end portion 226 and a bottom second end portion 228. It will be understood that the shapes of the upper and lower rib may be varied, but where the longitudinal slots 120 are substantially uniform, the upper and lower rib are each configured to facilitate at least elastic deformation of the longitudinal slot 120 upon insertion of the upper or lower rib thereinto. It is this intimate engagement along the length thereof through the elastic deformation that provides for the sealing and, in turn, the vapor barrier on opposing sides of the rib.

The first end wall 204 is positioned at the first end of the body wall 202 and, as set forth above, is preferably perpendicular to the body wall 202. In the embodiment shown, the first end wall extends downwardly from the bottom surface 212, and projects downwardly beyond the bottom surface 212 to define a lower flange portion 262. In certain embodiments, it is helpful to line an inside surface of the lower flange portion 262 with an adhesive or sealant (such as butyl rubber). The first end wall 204 includes inside surface 250, outside surface 252, and extends from lower end 254 to upper end 256. The upper end 256 includes lower flange portion 262. It is contemplated that the lower flange portion 262 extends upwardly a distance sufficient to provide an effective surface for the application and retention of an adhesive or sealant.

The lower flange portion 262 at a lower end on the outside surface 252 thereof includes a capillary break 260 (in the form of a relief portion which tapers toward the upper edge). As set forth in the incorporated references, the capillary breaks the water tension between it and the cladding or building substrate with which it is in contact so as to act as anti-capillary action grooves for water trapped therebetween or drawn into the joints.

A first reinforcement channel 258 is defined on one of the inside surface and the outside surface of the first end wall, and preferably on the inside surface thereof. The first reinforcement channel 258 includes upper clip portion 264 and lower clip portion 266 spanned on one side by surface 268 and open to the other side defining slot 269. The channel is generally parallel to the outside surface 252 and generally extends the entirety of the inside surface 250 below the bottom surface 212 of the body wall 202.

As will be explained below, first end wall strip 302 is slidably introduced into the first reinforcement channel 258. In certain embodiments, the first end wall strip 302 is relatively snug within the first reinforcement channel 258. Preferably, the first end wall strip 302 comprises a metal member, such as an aluminum, magnesium, steel, galvanized steel or another material. Of course, it is contemplated that the first end wall strip 302 comprises a composite member of a configuration that is the same or different than that of the bracket member. It is preferred that the first end wall strip 302 comprises a member of ductility sufficient so as to receive and be pierced by a fastener or the like, while retaining the fastener therein.

It will further be understood that a guide notch 267 extends on the outside surface 252 and along the length thereof. The guide notch 267 is provided so as to provide a user with a tactile feel for where to begin the insertion of a fastener. By initiating a fastener at the guide notch, it is such that the fastener will be directed into contact at an appropriate portion of the first end wall strip 302 positioned within the first reinforcement channel 258.

The second end wall 206 as shown in FIG. 7 is positioned at the second end of the body wall 202, and is preferably perpendicular to the body wall 202 (and parallel to the first end wall 204). In the embodiment shown, the second end wall extends downwardly from the bottom surface 212 of the body wall 202.

The second end wall includes inside surface 270 and outside surface 272 which extend from inner end 274 (which is at the junction with the body wall 202), to outer end 276. A capillary break 286 having a configuration that matches the capillary break 260 of the first end wall 204.

A second reinforcement channel 278 is defined in one of the inside surface and the outside surface of the second end wall, and preferably on the inside surface thereof. The second reinforcement channel includes outer clip portion 280 and inner clip portion 282 which are spanned on one side by surface 284 and which define slot 281 on the other side thereof. The channel is generally parallel to the outside surface 272 of the second end wall, and generally extends the entirety of the inside surface below the lower surface 212 of the body wall 202.

As with the first end wall 204 above, second end wall strip 304 is slidably introduced into the second reinforcement channel 278, preferably, relatively snug therewithin. Preferably, the same materials are utilized for the second end wall strip 304 as with the first end wall strip 302.

In other configurations, the reinforcing strips can be coupled to the body in other manner, such as, for example being adhered to the body, or being coupled to the body through fasteners or the like. In other configurations, the reinforcing channels can be omitted and the reinforcing strips can be applied directly to and coupled directly to the body. In still other configurations, the first and second strips may be formed from a material other than a metal member, such as, a polymer member, a reinforced member or members that are composites that include metal components.

The insulation 16 may comprise any number of different types of insulation, including, but not limited to fiberglass insulation, mineral wool, blown insulation, other fiber based insulation, polymer based insulation, or combinations of the same. It will further be understood that the insulation may be of varying types throughout a single installation.

It will further be understood that various barrier layers or structures are contemplated for use between the roof substrate 106 and the bracket member, and/or between the bracket member and the sliding clips 104.

In operation, with reference to FIG. 6, instead of mounting the interlocking panels and the sliding clips directly onto substrate 106, the structure is configured to couple a bracket member 14 therebetween. In such a construction, the bracket member 14 is coupled to the substrate 106 so as to be generally perpendicular to the interlocking panels. The sliding clips 104 are then coupled to the bracket member, with the sliding clips coupling the interlocking panels and thereby controlling the position thereof. Insulation 16 can be positioned and maintained in position by the bracket members. Such a configuration provides additional insulation while permitting use and operation of the roofing system of the prior art.

In another configuration, and with reference to FIG. 7, a pair of bracket members 14 can be positioned in a side by side configuration so as to provide a larger surface upon which the sliding clip 104 can be positioned. As with the construction shown in FIG. 6, the insulation extends between the bracket members. It will be understood that the bracket members in each configuration are generally perpendicular to the interlocking panels, however, they may be positioned orthogonal thereto. In addition, in some installations, it may be desirable to have some bracket members extend perpendicular to the disclosed bracket members to enhance rigidity of the structure.

It is contemplated that the bracket members extend continuously from one end of the structure to the other, and each bracket member includes a plurality of sliding clips coupled thereto. However, in other configurations, short bracket members can be discretely and separately coupled to only one or a few sliding clips. In such a configuration, multiple shorter bracket members may span across the substrate in a linear or an offset fashion.

As will be understood, generally, a space exists between the interlocking panels and the bracket member, and the insulation in the configurations shown. While not required, generally it is desirable to maintain such a spacing.

The foregoing description merely explains and illustrates the disclosure and the disclosure is not limited thereto except insofar as the appended claims are so limited, as those skilled in the art who have the disclosure before them will be able to make modifications without departing from the scope of the disclosure.

Claims

1. A roof construction comprising:

a substrate;

a plurality of bracket members coupled to the substrate;

a plurality of sliding clips coupled to the plurality of bracket members; and

a plurality of interlocking panels coupled to the sliding clips.

2. The roof construction of claim 1 wherein the substrate comprises a one of a flat and an oblique surface.

3. The roof construction of claim 1 wherein at least one of the bracket members includes a first end wall and a second end wall with a body wall spanning therebetween, the first end wall is coupled to the substrate, with a plurality of sliding clips coupled to the second end wall.

4. The roof construction of claim 3 wherein the first end wall and the second end wall are parallel to each other with the body wall being perpendicular to each of the first and second end walls.

5. The roof construction of claim 4 wherein the interlocking panels comprise metal panels having a cross-sectional configuration.

6. The roof construction of claim 3 wherein insulation is positioned between the substrate and the plurality of interlocking panels.

7. The roof construction of claim 3 wherein the first end wall further includes a first reinforcement channel, with a first end wall strip slidably positioned therein and the second end wall further includes a second reinforcement channel, with a second end wall strip slidably positioned therein.

8. The roof construction of claim 7 wherein the first reinforcement strip and the second reinforcement strip each comprise a metal member.

9. The roof construction of claim 3 wherein the sliding clips comprise a metal member.

10. The roof construction of claim 1 wherein at least a pair of bracket members are positioned in an abutting side by side configuration, with at least one of the plurality of sliding clips being coupled to each of the pair of bracket members that are positioned in a abutting side by side configuration.