Roof construction

• US 4,244,151 A
• Filed: 04/18/1979
• Issued: 01/13/1981
• Est. Priority Date: 04/18/1979
• Status: Expired due to Term

• Current Assignee: SMN Corp. (Sony Group Corp.)
• Original Assignee: SMN Corp. (Sony Group Corp.)
• Inventors: Seem, Charles T.
• Primary Examiner(s): Bell, J. Karl
• Application Number:
  US06/031,228
• Time in Patent Office: 636 Days
• Field of Search: 52/58, 52/592-595, 52/403, 52/404, 52/309.9, 52/520, 52/556
• US Class Current: 52/60
• CPC Class Codes: E04D 13/1415 Junctions to walls extending above the perimeter of the roof trimming strips, edge strips or fascias retaining the roof sheathing E04D13/155
• CPC Class Codes: E04D 13/15 Trimming strips; Edge strips; Fascias; Expansion joints for roofs wall copings E04D3/405; drainage borders E04D13/0459; joints in general E04B1/68
• CPC Class Codes: E04D 3/351 at least one of the layers being composed of insulating material, e.g. fibre or foam material
• CPC Class Codes: E04D 3/355 the insulating layers of adjacent slabs having cooperating edges
• CPC Class Codes: E04D 3/358 with at least one of the layers being offset with respect to another layer

Abstract

A roof construction for use upon a deck or pre-existing roof which includes a series of elongated coplanar roof panels assembled edge-to-edge at their ends in a line and top-to-bottom at right angles thereto juxtaposed over said roof or deck. Each roof panel comprises a thin metallic skin having a rectangular top plate with a downturned front edge along its length. Below the front edge is an assembly slot bounded by an outturned anchor plate adapted for securing to said roof. A series of snap lock stops are formed in said panel and extend into said assembly slot. The top plate has a downturned rear edge which terminates in a flexible outturned assembly plate spaced from and projecting rearwardly of the top plate. The assembly plate terminates in a reverse-turned snap lock flange which extends above said assembly plate. An elongated body of foam plastic material underlies the top plate, the assembly plate and is anchored within the panel with its bottom surface extending to the anchor plate adapted to cooperatively engage the deck or roof. The assembly plate and underlying portion of said body defines a tongue which is snugly nested within the corresponding assembly slot of an adjacent panel, with the lock flange of the one panel snapping into interlocking retaining engagement with the snap lock stops of the adjacent panel.

Claims

1. In a roof construction for use upon a deck or pre-existing roof, a series of elongated coplaner roof panels assembled edge-to-edge at their ends in a line, and top-to-bottom in a line at right angles thereto, juxtaposed over said deck or roof;

each roof panel comprising a thin metallic skin having a rectangular top plate;

a downturned front edge along its length;

said front edge terminating in a return plate, which terminates in a downturned upright wall, in turn, terminating in an outturned anchor plate spaced from and projecting forwardly of said top plate; and

defining with said return plate an assembly slot;

a series of aligned struckout snap lock stops formed in said return plate and extending into said assembly slot;

a downturned rear edge along the opposite edge of said top plate;

said rear edge terminating in a flexible outturned assembly plate spaced from and projecting rearwardly of said top plate;

a reverse-turned snap lock angle flange at the edge of and extending above said assembly plate;

an elongated body of foam plastic material underlying said top plate, said assembly plate and projected into portions of said panel between said top plate and return plate and anchored therein;

its bottom surface extending to said anchor plate and coplanar therewith and adapted to cooperatively engage said deck or roof;

and a series of fasteners securing said anchor plate to said deck or roof;

the assembly plate and underlying portion of said foam plastic body along one edge of a panel defining a tongue snugly nested within the corresponding assembly slot along the opposite edge of an adjacent panel with said lock flange of one panel snapping into interlocked retaining engagement with snap lock stops of said adjacent panel.

2. In the roof construction of claim 1, said metallic skin being aluminum.

3. In the roof construction of claim 1, a flexible sealant bead mounted on said anchor plate within said assembly slot and compressively engageable with said tongue and said snap lock angle flange.

4. In the roof construction of claim 1, a flexible sealant foam tape mounted on and secured to said assembly plate at said rear edge and compressively and sealingly engageable with the downturned front edge of said adjacent panel.

5. In the roof construction of claim 3, a flexible sealant foam tape mounted on and secured to said assembly plate at said rear edge and compressively and sealingly engageable with the downturned front edge of said adjacent panel.

6. In the roof construction of claim 5, a flexible sealant bead interposed between the downturned rear edge of one panel and the downturned front edge of said adjacent panel bearing upon said sealant foam tape and closing the gap between the top plates of adjacent panels.

7. In the roof construction of claim 1, each of said roof panels having an undercut assembly slot at one end;

and

a projecting tongue at its opposite end, said latter assembly slot and tongue being of the same construction as herein defined with respect to the first mentioned assembly slot and tongue of each panel

with the tongue at the end of one panel snugly and sealingly projected into the assembly slot on the end of the adjacent panel, and with the corresponding snap lock angle flange at the edge of said tongue retainingly interlocked with the corresponding snap lock stops extending into the assembly slot at the end of the adjacent panel.

8. In the roof construction of claim 1, there being a drip edge of right angular shape overlying and secured to and along peripheral portions of said deck or roof, underlying the roof panels assembled thereon;

the ends of the roof panels along the roof periphery being cut away for alignment with said roof periphery;

a roll-formed closure strip covering the exposed edges of said panels and overlying a side portion of the roof periphery and secured thereto;

and a pair of spaced arms on said strip with their free ends having reverse-turned opposed barbs, projected into adjacent panels upon the top and bottom of the foam plastic body and retainingly embedded therein.

9. In the roof construction of claim 8, a sealant bead applied to the top edge of said closure strip and in sealing engagement with the top of adjacent roof panels.

10. In the roof construction of claim 1, there being a drip edge of right angular shape overlying and secured to and along peripheral portions of said deck or roof, underlying the roof panels assembled thereon;

the ends of the roof panels along the roof periphery being cut away in alignment with said roof periphery;

an elongated clip overlying and secured to the top peripheral edges of the panels along the roof periphery, said clip being inclined upwardly and terminating in a reverse-turned anchor flange bearing upon said panels;

and a roll-formed closure strip covering the exposed edges of said panels, overlying a side portion of the roof periphery;

and a pair of spaced arms on said strip with their free ends having revese-turned opposed barbs;

one arm engaging the undersurface of the foam plastic body of each roof panel with its barb retainingly embedded therein;

the other arm being inclined downwardly with its barb projected under and retainingly engaging said clip anchor flange.

11. In the roof construction of claim 10, an elongated bead of sealant material extending into the space between the upper barb and said panels and affixed thereto.

12. In the roof construction of claim 1, a wall along one side of the roof periphery and projecting above said roof panels;

and a weatherproof flashing between said roof panels and wall including a base clip plate or right-angular shape overlying and bearing upon said roof panels and secured thereto;

a portion of said base clip plate bearing against said wall;

the inner end of said base clip plate having a reverse-turned first corner angle;

there being a struck out anchor stop projected from and below said base clip plate adjacent its corner angle;

an upright clip plate of right angular shape overlying said base clip plate and said wall and secured to said wall;

the upper edge of said upright clip plate having reverse-turned second corner angle facing said first corner angle;

and an elongated inclined closure plate, along its upper edge projected into said second corner angle;

there being a reverse-turned third corner angle along the lower edge of said closure plate;

said third corner angle terminating in a reverse-turned locking flange extending under said first corner angle and retainingly interlocked with said anchor stop.

13. In the roof construction of claim 12, a strip of resilient foam sealant tape upon one side of said base clip plate and said upright clip plate in sealing engagement with said roof panels and wall respectively;

whereby any relative movement between said base clip plate and upright clip plate due to changing weather conditions will not effect the seals between said plates and said panels and wall respectively.

14. In the roof constructon of claim 13, a first elongated strip of sealant materials interposed between the upper end of said upright clip plate and wall;

and a second elongated strip of sealant material overlying the lower edge of said closure plate and the adjacent roof panels.

15. In a roof construction for use upon a deck or pre-existing roof, a series of elongated coplanar roof panels assembled edge-to-edge at their ends in a line, and top-to-bottom in a line at right angles thereto, juxtaposed over said roof or deck;

each roof panel comprising a thin metallic skin having a rectangular top plate;

a downturned front edge along its length;

said front edge having an undercut assembly slot terminating in an anchor plate spaced from and projecting outwardly of said top plate;

means securing said anchor plate to said roof or deck;

a series of aligned struck-out snap lock stops in said panel and extending into said assembly slot;

a downturned rear edge along the opposite side of said top plate, terminating in a flexible outturned assembly plate spaced from and projecting outwardly of said top plate;

a reverse-turned snap angle flange at the edge of and extending above said assembly plate;

and an elongated body of foam plastic material underlying said top plate, said assembly plate and projected into portions of said panel between said top plate and said assembly slot and secured thereto;

its bottom surface extending to said anchor plate and coplanar therewith and adapted to cooperatively engage said deck or roof;

the assembly plate and underlying portion of said foam plastic body along one edge of a panel defining a tongue snugly nested within the corresponding assembly slot along the opposite edge of an adjacent panel with the angle flange of one panel snapping into interlocked retaining engagement with snap lock stops of said adjacent panel.