MULTI-LAYER ROOF SYSTEM

Abstract

The present invention provides a multi-layer roof system, and an installation method. The multi-layer roof system comprises a roof truss; and a multi-layer panel comprising a base layer, a plurality of intermediate layers, and at least one coating layer placed over the plurality of intermediate layers. The base layer comprises at least one membrane of waterproof or water resistant material configured to provide an under-laminate capable of being affixed to a building structure with no screws. The plurality of intermediate layers comprises a first intermediate layer, a second intermediate layer and a third intermediate layer. The first intermediate layer comprises a cooling layer. The second intermediate layer comprises a mesh layer. The third intermediate layer comprises a reflecting layer. The at least one coating layer may comprise a plurality of coating layers. The multi-layer roof system provides a multi-layer building roof structure configured to be both structurally sound and energy efficient.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application Ser. No. 63/294,316 filed on Dec. 28, 2022, the contents of which are incorporated by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT

Not Applicable

REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISC AND INCORPORATION-BY-REFERENCE OF THE MATERIAL

Not Applicable.

COPYRIGHT NOTICE

Not Applicable

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates generally to building structures, and more particularly, to a multi-layer roof system with a temperature insulating and cooling layer, and a method for installing the multi-layer roof system on a building structure.

Description of the Related Art

Countless civilizations throughout history have blossomed by taking advantage of a geographical terrain that could meet the demands of the time. These demands follow certain predictable patterns, as they usually involved the search for the most primal human desires according to Maslow's Hierarchy of Needs: food, water, and shelter. For them, dealing with a thunderstorm, hurricane, tornado, earthquake, and other natural disasters meant a fight for survival against an omnipotent evil, commonly leading to the deaths of their family and friends. For this reason, ancient civilizations prescribed to the idea of protecting themselves from the environment and its devastating qualities. As Carl Sagan once said, “we've arranged a civilization in which most crucial elements profoundly depend on science and technology,” and although these terms were not familiar then, science and technology were both employed by the first engineers of protective shelters.

According to the Roman architect Vitruvius, the earliest form of architecture was a frame of timber branches finished in mud, called a primitive hut. The Primitive Hut then became a concept that explored the relationship between man and the natural environment as the fundamental basis for the creation of architecture. As aforementioned, this relationship was not particularly forgiving, and the necessity for protection was what gave rise to architecture. Not only did design evolve into a more sophisticated and mathematical approach, but also did the science behind the materials used for construction. Early building materials were perishable, as humans utilized their surroundings to construct a shelter usually consisting of leaves, branches, animal hides, mud, or the like. Through more trial and error, clay, stone, and timber became the staple materials for which to build a more durable and robust shelter. Centuries later, the vastly complicated science of synthetic materials meshed to create even stronger homes proper for the needs of the time.

Although the “needs of the time” have remained relatively constant throughout history, the impacts of the escalation of human population following the industrial revolution gave rise to new and unexpected needs that demand the world's attention. The common one being climate change, with yearly increases in carbon dioxide levels and global temperature rise at unprecedented rates, the consequences on the environment are catastrophic and vast—so much so that it is impossible to detect every change occurring around the globe attributed to this phenomenon. One fact that scientists are certain of is the increased potency of natural disasters, more specifically of hurricanes. For these exceptionally destructive hurricanes to form, warm ocean water and humidity are necessary, and the warmer the ocean, the more powerful the storm.

The site of impact of these hurricanes are the coastal shorelines, which create 40% of America's jobs and are responsible for 46% of America's GDP. The economic impact of these strengthening storms is astounding, with some costing over 100 billion dollars in property damage along with slowing the economic performance of the affected areas. The technology for constructing protective shelters and houses around hurricane prone environments requires a dramatic change to withstand the new intensity of storms.

Accordingly, there is need for a solution to at least one of the aforementioned problems. For instance, there is a need for roof structures capable of withstanding impact from airborne debris scattered about during serious weather events, including but not limited to hurricanes. Further, there is an established need for roof structure that provides temperature insulation and cooling, which is energy efficient. Additionally, there is a need for a roof system designed to be waterproof and durable, long-lasting, and capable of withstanding serious weather events. In addition, there is a need for a roof system that is easily installed.

The above-described deficiencies of today's systems are merely intended to provide an overview of some of the problems of conventional systems, and are not intended to be exhaustive. Other problems with the state of the art and corresponding benefits of some of the various nonlimiting embodiments may become further apparent upon review of the following detailed description.

BRIEF SUMMARY OF THE INVENTION

The present invention is directed to a multi-layer roof system comprising a temperature insulating and cooling layer. The system is configured for installation on a building structure to provide a roof that is both structurally sound and energy efficient. The present invention also provides a method for installing the multi-layer roof system on the building structure.

In a first implementation, the present invention provides a multi-layer roof system. The multi-layer roof system comprises at least one roof truss, and a plurality of multi-layer roof system panels.

In one aspect, each multi-layer roof system panel comprises a base layer, a plurality of intermediate layers, and at least one coating layer placed over the plurality of intermediate layers.

In another aspect, the base layer comprises at least one membrane of waterproof or water-resistant material, configured to provide an under-laminate capable of being affixed to a building structure with no screws.

In yet another aspect, the plurality of intermediate layers comprises a first intermediate layer, a second intermediate layer and a third intermediate layer. The first intermediate layer comprises a temperature insulating layer. The temperature insulating layer may be a cooling layer. The second intermediate layer comprises a mesh layer. The third intermediate layer comprises a reflecting layer.

In a further aspect, the at least one coating layer may comprise a plurality of coating layers.

In a still further aspect, the multi-layer roof system of the present invention may comprise overflow scuppers (wall outlets) to permit rainwater flow off the roof so that the roof is not overloaded from a buildup of water. Overflow scuppers may ensure that perimeter or edge walls, or other roof extensions, will not block rainwater runoff.

In one aspect, the multi-layer roof system provides a multi-layer roof structure configured to be both structurally sound and energy efficient. The multi-layer roof system of the present invention is durable and long-lasting. The multi-layer roof system may provide a 100-year warranty.

In one aspect, the present invention provides an unprecedented multi-layer roof system which may be capable of installation in significantly less time than previous roofing solutions.

Accordingly, a method for installation of the multi-layer roof system and all components thereof is provided. The multi-layer roof system may be installed on the building structure by installing the at least one roof truss on the building structure and securing the plurality of multi-layer roof system panels to the at least one roof truss, to provide a structurally sound, energy efficient multi-layer roof.

In one aspect, the installation method complies with current highly specific regulations for replacement of roofing which must be followed.

In one aspect, the multi-layer roof system may be installed to replace at least a portion of a roof of a building structure. In one aspect, the multi-layer roof system may be installed to entirely replace an existing roof.

In one aspect, an existing roof deck is retained, and an existing wood roof deck is renailed to comply with one or more Local, State or Federal regulations. In some situations, a roof deck is usually concealed prior to removing the existing roof system.

In one aspect, where a building structure has interior exposed ceilings, such as open beam ceilings where the underside of the roof decking can be viewed from below, a homeowner may wish to maintain the existing architectural appearance. Therefore, roofing nail penetrations of the underside of the decking may not be acceptable. The multi-layer roof system of the present invention may permit the owner to maintain the original appearance, because the first layer has no hardware.

These and other objects, features, and advantages of the present invention will become more readily apparent from the attached drawings and the detailed description of the preferred embodiments, which follow.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention, and the attendant advantages and features thereof, will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:

FIG. 1 presents a top perspective view of a multi-layer roof system installed on a building structure in accordance with the principles of the invention;

FIG. 2 presents a perspective cutaway view of a multi-layer roof system in accordance with the principles of the invention;

FIG. 3 presents a side elevation view of the multi-layer roof system as in FIG. 2, in accordance with the principles of the invention;

FIG. 4 presents a schematic view of the fasteners of the multi-layer roof system in accordance with the principles of the invention; and

FIG. 5 presents a side cross-sectional view of sealing at vertical or horizontal joints between panels of the multi-layer roof system in accordance with the principles of the invention.

Like reference numerals refer to like parts throughout the several views of the drawings.

DETAILED DESCRIPTION

The invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

The disclosed subject matter is described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the various embodiments of the subject disclosure. It may be evident, however, that the disclosed subject matter may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate describing the various embodiments herein. Various embodiments of the disclosure could also include permutations of the various elements recited in the claims as if each dependent claim was a multiple dependent claim incorporating the limitations of each of the preceding dependent claims as well as the independent claims. Such permutations are expressly within the scope of this disclosure.

Unless otherwise indicated, all numbers expressing quantities of ingredients, dimensions, reaction conditions and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about”. The term “a” or “an” as used herein means “at least one” unless specified otherwise. In this specification and the claims, the use of the singular includes the plural unless specifically stated otherwise. In addition, use of “or” means “and/or” unless stated otherwise. Moreover, the use of the term “including”, as well as other forms, such as “includes” and “included”, is not limiting. Also, terms such as “element” or “component” encompass both elements and components comprising one unit and elements and components that comprise more than one unit unless specifically stated otherwise.

For ease of understanding, the following definitions will apply throughout this description. However, no definition should be regarded as superceding any art-accepted understanding of the listed terms.

As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. For purposes of description herein, the terms “upper”, “lower”, “left”, “rear”, “right”, “front”, “vertical”, “horizontal”, and derivatives thereof shall relate to the invention as oriented in FIG. 1. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

Various embodiments of the disclosure could also include permutations of the various elements recited in the claims as if each dependent claim was a multiple dependent claim incorporating the limitations of each of the preceding dependent claims as well as the independent claims. That is, the combinations of the various components of the invention are not limited to those combinations expressly shown in the Figures. Unless expressly stated otherwise, components described in one embodiment may be interchanged with components of the same name found in other embodiments. Such permutations are expressly within the scope of this disclosure.

The present invention is directed to a multi-layer roof system with a cooling layer. The system may include a multi-layered roof structure configured for installation on a building structure. The multi-layer roof system is configured to be both structurally sound and energy efficient. The present invention also provides a method for installing the multi-layer roof system on a building structure.

Shown throughout the Figures, the present invention is directed to a multi-layer roof system, shown generally at 100. The multi-layer roof system 100 may comprise a multi-layered roof structure configured for installation on an exemplary building structure 102 as seen at FIG. 1. The building structure 102 may be any suitable building structure.

For example, the multi-layer roof system may be installed upon any suitable home building structure. In some embodiments, the home building structure may have sides made of a galvanized steel covered with a gypsum board. A home building structure on which the multilayer roof system is installed may be seismic proof against earthquakes. The multi-layer roof system may be CAT-5 rated.

Referring to FIG. 2, the multi-layered roof structure 100 may comprise a plurality of multi-layer panels 104. Each panel 104 has a top 106, a bottom 108, a right side 110, a left side 112, a front 114 and a rear 116. Each panel 104 may have any suitable dimensions. In an exemplary embodiment, each panel may have dimensions of four (4) feet by eight (8) feet (4′×8′ sheet).

In a first implementation, the multi-layer roof system 100 may comprise a roof truss 120, a base layer 130 configured for placement over the roof truss 120, a plurality of intermediate layers 150 configured for installation over the base layer 130, and at least one coating layer 180 configured for placement over the plurality of intermediate layers 150.

The roof truss 120 may comprise a cold-formed steel roof truss 122. The base layer 130 may comprise at least one membrane 132 of waterproof or water-resistant material. In some embodiments, the base layer 130 is configured to provide an under-laminate capable of being affixed to a building structure with no screws. In other embodiments, the base layer may comprise a roof sheath 134. The roof sheath 134 may be made of any suitable material. In some embodiments, the base layer 130 may include a roof sheathing layer 136 which comprises a SURE-BOARD® brand S-200 construction panel wall board. SURE-BOARD® brand S-200 construction panel wall boards are commercially available from Specialty Hardware, LLC, located in Scottsdale, Ariz. 85258, United States of America.

The plurality of intermediate layers 150 may comprise a first intermediate layer 152, a second intermediate layer 160, and a third intermediate layer 166. The first intermediate layer 152 may comprise a thermal insulating layer 154. The thermal insulating layer may be a cooling layer 156. The cooling layer 156 may be any suitable material, such as, for example without limitation, SHARKSKIN® Ultra SA Underlayment 158. The second intermediate layer 160 may comprise a mesh layer 162. The mesh layer may be any suitable material, such as, for example without limitation, SHARKSKIN® ventilated roof mat 164. The third intermediate layer 166 may comprise a reflecting layer 168. The reflecting layer may be any suitable material, such as, for example without limitation, SHARKSKIN® radiant barrier 170. SHARKSKIN® brand underlayment and barriers are commercially available from Kirsch Research and Development, LLC of Simi Valley, Calif. 93065, United States of America.

The at least one coating layer 180 is configured for placement over the plurality of intermediate layers. In some embodiments, the at least one coating layer 180 may comprise a coating layer such as, for example without limitation, GULFLOK™ brand metal roofing, GULFRIB™ brand metal roofing, OCEANGUARD(stylized)® brand metal roofing, GULF COAST SUPPLY & MANUFACTURING® brand metal roofing, or combinations thereof. GULFLOK™, GULFRIB™, OCEANGUARD(stylized)®, and GULF COAST SUPPLY & MANUFACTURING® brand metal roofing products are commercially available from Gulf Coast Supply & Manufacturing, LLC, located in Horseshoe Beach FLORIDA 32648, United States. In some embodiments, where the multi-layer roof system is installed on a building structure located within 1500 ft of salt water, the at least one coating layer 180 may comprise OCEANGUARD(stylized)® brand metal roofing. In some embodiments, the at least one coating layer 180 may comprise a plurality of coating layers.

Referring to FIG. 3, the multi-layer roof system 100 may further comprise a perimeter or edge wall, also referred to as fascia 190 (or fascia board). A fascia vent 192 is also provided. A nonlimiting example of a suitable fascia vent 192 may be a COR-A-VENT® brand fascia vent 194, which may comprise laminated corrugated airflow channel strips. COR-A-VENT® brand rooftop ventilating units in the nature of laminated corrugated airflow channel strips, are commercially available from Cor-A-Vent, Inc., located in Mishawaka, Ind. 46546, United States of America.

The multi-layer roof system 100 of the present invention may further comprise overflow scuppers 196 (wall outlets, also referred to as drip edge 196) to permit rainwater flow off the roof so that the roof is not overloaded from a buildup of water. Overflow scuppers 196 may ensure that perimeter or edge walls, or other roof extensions, will not block rainwater runoff. Further, it may be required by Federal, State or Local regulations to install overflow scuppers. For example, overflow scuppers are required in accordance with 2020 Florida Building Code (FBC) Chapters 15 and 16.

The multi-layer roof system may be free from wood, wood containing materials, and tar paper. As no wood is used, there will be no termites or wood rot.

The system and its components may be made of any suitable materials, such as, for example without limitation, waterproof materials of any type, metal, reflective materials, mesh made of any suitable materials, and combinations thereof.

The roof system may comprise a waterproof membrane, a metal roof layer with cooling properties, a reflecting layer and at least one mesh layer. In some embodiments, a layer may comprise a metal backing over which one or more other components are adhered or laminated.

Referring now to FIG. 4, a schematic view of the sheath fastener 200 of the roof sheath 134. The roof sheath 134 may have any suitable dimensions. In an exemplary embodiment, the roof sheath may have dimensions of four (4) feet by eight (8) feet (4′×8′ sheet). The roof sheath 134 may be fastened or mounted in any suitable manner well known to those skilled in the art, but preferably includes a type of riveting or screw-type fitting adequate for use as a steel fastener that securely fastens the roof sheath. The fasteners 200 may be #10×¾″ sheet metal screws, and for a roof sheath 134 having dimensions of 4′×8′, 48 fasteners may be provided per 4′×8′ sheet. A plurality of rows of framework studs 202 may be provided, each framework stud 202 having a plurality of screw bores 204. The framework studs 202 may be any suitable dimensions. For example, each framework stud 202 may have a width of about 2.5 inches (2.5″), and may have a plurality of screw bores 204 spaced about 6″ apart. The framework studs 202 may be spaced about 1 foot, 4 inches (16″) apart. Though three framework studs 202 are shown, this is merely illustrative and should not be considered in limitation of the present invention.

The roof sheath 134 may be any suitable roof sheath 134. A nonlimiting example of a roof sheath component may include a roof sheathing layer 136 which comprises a SURE BOARD® brand S-200 construction panel wall board. The roof sheath 134 and sheath fasteners 200 further comply with Federal, State and Local requirements, for example FL, and Miami/Dade NOA (Notice of Acceptance).

FIG. 5 presents a side cross-sectional view of sealing at vertical or horizontal joints between roof sheath 134 panels of the multi-layer roof system 100 in accordance with an exemplary embodiment of the present invention. FIG. 5 also shows the typical sealing detail at a vertical or horizontal joint between roof sheath 134 panels, such as a roof sheathing layer 136 which may comprise SURE-BOARD® brand S-200 construction panel wall boards. The framework stud 202 may be any suitable metal stud. For example, the framework stud 202 may be a metal stud. Further the framework stud 202 may be min. 0.044 thick grade 40 g-90 galvanized steel. In embodiments in which the roof sheathing layer 136 comprises SUREBOARD® brand S-200 construction panel wall boards, a framework stud of a min. 0.044 thick grade 40 g-90 galvanized steel is always required at all joints between the SURE-BOARD® brand S-200 construction panel wall boards to provide support for the panels at vertical or horizontal joints all around the SURE-BOARD® brand S-200 construction panel wall boards of the roof sheathing layer 136.

The framework stud 202 may be attached or mounted to a cement board 210. The cement board 210 may be any suitable cement board. In some embodiments, for example, the cement board 210 may be a ½″-thick cement board. The ½″-thick cement board may be a PERMABASE® brand cement backer board. PERMABASE® brand cement backer boards are commercially available from Permabase Building Products, LLC of Charlotte, N.C. 28211, United States of America. On the cement board 210, there may be provided one or more coatings. In some embodiments, the cement board may be provided with a base coat 212 and a top coat 216. The base coat 212 and the top coat 216 may be any suitable base coat and top coat. In some embodiments, the base coat 212 may be an ACRODRY™ base coat 214, and the top coat 216 may be an ACROCRETE® finish coat 218. ACRODRY™ base coat and ACROCRETE® construction materials and ready mixed acrylic stucco exterior materials are commercially available from BASF Wall Systems of Jacksonville, Fla. 32224, United States of America and BASF LEC CONSTRUCTION CHEMICALS, LLC LLC, of Florham Park, N.J. 07932, United States of America. In some embodiments, the ½″ thick cement board 210 may be a ½″ thick permeable cement board adhered to galvanized steel skin with an acrylic emulsion. The cement board 210 may be a SURE-BOARD® brand S-200 construction panel wall board, that is used as part of the roof sheathing layer 136.

In some embodiments, a fiberglass mesh 220 may be embedded into the base coat 212. In some embodiments, the fiberglass mesh 220 may be a 9¼″ wide continuous full height or full width impact fiberglass mesh.

As noted, each framework stud 202 may have a width of about 2.5 inches (2.5″), and may have a plurality of screw bores 204 spaced about 6″ apart. The framework studs 202 may be spaced about 1 foot, 4 inches (16″) apart. In some embodiments, #10×¾″ s.m.s. may be located at about 2¼″ from an end 8″, 13½″, 14″, 7½″ to a horizontal top track and a horizontal bottom track, and (17) #10×1½″ s.m.s. may be located starting at 6″ from a bottom at 6″ o.c. max. to the vertical studs spaced at 16″ o.c. max.

In one aspect, the multi-layer roof system provides a multi-layer roof structure configured to be both structurally sound and energy efficient. The multi-layer roof system of the present invention is durable and long-lasting. The multi-layer roof system may provide a 100-year warranty.

In one aspect, the present invention provides an unprecedented multi-layer roof system which may be capable of installation in significantly less time than previous roofing solutions.

Accordingly, in a second implementation, a method for installation of the multi-layer roof system and all components thereof is provided as described herein. The multi-layer roof system may be installed on any suitable building structure.

For example, the multi-layer roof system may be installed upon any suitable home building structure. In some embodiments, the home building structure may have sides made of a galvanized steel covered with a gypsum board.

A home building structure on which the multi-layer roof system is installed may be seismic proof against earthquakes. The multi-layer roof system may be CAT-5 rated. The multilayer roof system may be fully seismic rated. The multi-layer roof system may have a warranty of 100 years.

The installation method complies with current highly specific regulations for replacement of roofing which must be followed. For example, currently in Florida all new and re-roof construction must be in accordance with the 2020 Florida Building Code (FBC), Chapters 15 and 16, and all sections pertaining to High-Velocity Hurricane Zones. Further, all Federal, State, and Local regulations must be followed by all working at the jobsite. In addition, all installation work to be performed by qualified and training roofing installers. All unfinished work must be covered to prevent water intrusion into the home.

In one aspect, the multi-layer roof system may be installed to replace at least a portion of a roof of a building structure.

In one aspect, the multi-layer roof system may be installed to entirely replace an existing roof. In fact, in some situations, Federal, State or Local regulations may require replacement of an entire roof. For example, under the 2020 FBC, Chapter 15, paragraph 1511.1.1, not more than 25 percent of the total roof area or roof section of any existing building or structure may be repaired, replaced, or recovered in any 12-month period unless the entire existing roofing system or roof section is replaced.

In one aspect, an existing roof deck is retained, and an existing wood roof deck is renailed to comply with one or more Local, State or Federal regulations. For example, in accordance with the current provisions of FBC Chapter 16 (High-Velocity Hurricane Zones), a roof deck is usually concealed prior to removing the existing roof system.

Further, in situations where a building structure has interior exposed ceilings, such as open beam ceilings where the underside of the roof decking can be viewed from below, a homeowner may wish to maintain the existing architectural appearance. Therefore, roofing nail penetrations of the underside of the decking may not be acceptable. The multi-layer roof system of the present invention may permit the owner to maintain the original appearance as the first layer, has no hardware.

Once the roof is fastened, a coating may be placed upon an exterior layer of the roof system. In some embodiments, the exterior layer may be made of a high-strength, water resistant material. Additionally, a plurality of coats of a coating may be applied to the exterior layer. The coating may be any suitable coating. The coating is preferably waterproof and fireproof, capable of sealing the structure to wind and moisture intrusion.

For example without limitation, in some embodiments, a polyurea coating may applied to an outside-facing surface of an exterior or outermost layer prior to application of the exterior or outermost layer.

In some embodiments a plurality of coats of a MAX-SHIELD® coating may be placed on the roof system. MAX-SHEILD® is a “sealing polymer for use in water-based drilling fluid systems”, commercially available from Baker Hughes Incorporated, a Delaware Corporation, located in Houston, Tex., 77210, United States of America.

In some embodiments, up to about eight (8) coats of any suitable coating may be applied. In other embodiments, up to about eleven (11) coats may be applied.

In summary, in an exemplary embodiment, the present invention provides a multilayer roof system with a thermally insulating layer or a cooling layer, and a method for installing a multilayer roof system on a building structure as described. The multi-layer roof system comprises at least one roof truss, and a plurality of multi-layer roof panels configured for securement to the at least one roof truss. Each multi-layer roof panel comprises a base layer, a plurality of intermediate layers, and at least one coating layer placed over the plurality of intermediate layers. The base layer comprises at least one membrane of waterproof or waterresistant material. The base layer may be configured to provide an under-laminate capable of being affixed to a building structure with no screws. The plurality of intermediate layers comprises a first intermediate layer, a second intermediate layer and a third intermediate layer. The first intermediate layer comprises a cooling layer. The second intermediate layer comprises a mesh layer. The third intermediate layer comprises a reflecting layer. The at least one coating layer may comprise a plurality of coating layers. The multi-layer roof system may be installed on the building structure by installing the at least one roof truss on the building structure and securing the plurality of multi-layer roof panels to the at least one roof truss. The multi-layer roof system provides a multi-layer roof structure configured to be both structurally sound and energy efficient.

Since many modifications, variations, and changes in detail can be made to the described preferred embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Furthermore, it is understood that any of the features presented in the embodiments may be integrated into any of the other embodiments unless explicitly stated otherwise. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents.

Whereas, the present invention has been described in relation to the drawings attached hereto, other and further modifications, apart from those shown or suggested herein, may be made within the spirit and scope of this invention. Those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. Descriptions of the embodiments shown in the drawings should not be construed as limiting or defining the ordinary and plain meanings of the terms of the claims unless such is explicitly indicated. The claims should be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

Claims

1. A multi-layer roof system comprising:

at least one roof truss configured for installation on a building structure;

a plurality of multi-layer roof panels configured for securement to the at least one roof truss, each multi-layer roof panel comprising:

a base layer comprising at least one membrane of waterproof or water-resistant material, the base layer configured to provide an under-laminate capable of being affixed to a building structure with no screws;

a plurality of intermediate layers configured for installation over the base layer, the intermediate layers comprising a first intermediate layer, a second intermediate layer and a third intermediate layer, wherein: the first intermediate layer comprises a cooling layer; the second intermediate layer comprises a mesh layer; and the third intermediate layer comprises a reflecting layer; and at least one coating layer configured for placement over the over the plurality of intermediate layers;

whereby the multi-layer roof system may be installed on the building structure by installing the at least one roof truss on the building structure and securing the plurality of multi-layer roof panels to the at least one roof truss, to provide a structurally sound, energy efficient multi-layer roof.