Panelized roofing system

Patent metadata

Field	Value
Publication number	US-11608640-B2
Application number	US-202217752957-A
Country	US
Kind code	B2
Filing date	May 25, 2022
Priority date	May 25, 2021
Publication date	Mar 21, 2023
Grant date	Mar 21, 2023

Abstract

A roofing system including a plurality of roofing panels that can be releasably secured to rafters or other supports of the roof by connectors. In embodiments, the connectors can include first and second connectors, each of which can include a plate with a projection extending therefrom, and with the plates defining flanges on each side of the projection. The plates of the first and second connectors are configured to seat on and at least partially extend along one of the rafters of the roof structure and along exterior facing surfaces of adjacent ones of the roofing panels to releasibly secure the roofing panels to the rafters.

First claim

The invention claimed is:

1. A roofing system, comprising:
a plurality of rafters;
a plurality of roofing panels comprising at least a first roofing panel and a second roofing panel positioned on opposite sides of at least one rafter;
a membrane positioned over an upper surface of the first roofing panel and the second roofing panel;
a first connector secured to the at least one rafter;
a second connector positioned opposite the first connector; and
a plurality of fasteners, at least some of the fasteners configured to be extended through at least some of the first and second connectors and through the first and second roofing panels;
wherein the second connector is fastened to the first connector with adjacent peripheral side portions of the first roofing panel and second roofing panel engaged and held between the first connector and the second connector to couple the first roofing panel and second roofing panel together along the at least one rafter;
wherein the plurality of roofing panels further comprises a third roofing panel positioned downslope from the first roofing panel or the second roofing panel; and
wherein the membrane includes an overlap portion configured to at least partially overlap an upper surface of the third roofing panel so as to form a seal configured to resist migration of water between the third roofing panel and the first roofing panel or the second roofing panel.

2. The roofing system of claim 1 , wherein each of the first and second connectors comprises a pair of flanges and a projection located between the flanges, and wherein a first one of the flanges is fastened to the first roofing panel and a second one of the flanges is fastened to the second roofing panel with the projection at least partially received along a joint defined between the first roofing panel and the second roofing panel between the first and second roofing panels.

3. The roofing system of claim 2 , wherein the projection and the flanges of the first connector define a T-shaped cross-section of the first connector, and wherein the projection and the flange of the second connector define a T-shaped cross-section of the second connector.

4. The roofing system of claim 1 , wherein the first second connector is at least partially secured to the upper surface of the first roofing panel and to the upper surface of the second roofing panel with a sealant.

5. The roofing system of claim 1 , wherein the overlap portion is bonded to the upper surface of the third roofing panel and is configured to cover a seam formed between adjacent edges of the first roofing panel and the third roofing panel.

6. The roofing system of claim 1 , wherein at least some of the roofing panels of the plurality of roofing panels comprise oriented strand board; laminate panels, wood panels, metal panels, or a combination thereof.

7. The roofing system of claim 1 , wherein each of the roofing panels comprises a core, a first layer of material overlying the core, and a second layer of material underlying the core.

8. The roofing system of claim 7 , wherein the core comprises polyisocyanurate, polystyrene, PVC, polyethylene, polyamide, phenolic material, or a combination thereof; and the first and second layers each comprise a polymer material, metal, wood, or a combination thereof.

9. The roofing system of claim 7 , further comprising a third layer of material overlying the first layer of material, the third layer comprising a thermoplastic membrane, a gripping material layer having a plurality of gripping features configured to mechanically couple the first and second roofing panels together, or a combination thereof.

10. The roofing system of claim 1 , wherein the first and second roofing panels further comprise a first chamfer formed in the first roofing panel and the second roofing panel along the adjacent peripheral side portions thereof, and a second chamfer opposite the first chamfer and formed in the first and second roofing panels along the adjacent peripheral side portions thereof; wherein the first chamfer is configured to receive a projection of the first connector and the second chamfer is configured to receive a projection of the second connector when the first and second roofing panels are engaged between the first and second connectors.

11. The roofing system of claim 1 , wherein at least one of the first and second connectors further comprises a projection configured to engage a chamfer defined along the adjacent peripheral side portions of the first roofing panel and second roofing panel when the first and second roofing panels are engaged between the first and second connectors.

12. The roofing system of claim 1 , further comprising an adhesive applied between the overlap portion and the third roofing panel and configured to secure the overlap portion to an exterior surface of the third roofing panel.

13. A roofing system, comprising:
a plurality of rafters;
a plurality of roofing panels each configured to span a distance between adjacent rafters, each of the roofing panels comprising an upper surface and a lower surface;
a membrane positioned over the upper surface of the each of roofing panels and configured to resist migration of water therethrough; and
a plurality of connectors, including:
a first connector fastened to a rafter and configured to releasably attach to a first roofing panel and a second roofing panel;
a second connector opposite the first connector; and

a plurality of fasteners extending through the first and second connectors and through the first and second roofing panels to releasably secure the first and second connectors to the first and second roofing panels;
wherein the fasteners are configured to fasten the first connector to the rafter and fasten the second connector to the first connector with adjacent peripheral side portions of the first roofing panel and the second roofing panel engaged therebetween so as to couple the first roofing panel and second roofing panel together along the rafter;

wherein the membrane includes an overlap portion configured to at least partially overlap an upper surface of a third roofing panel downslope from the first roofing panel or the second roofing panel so as to form a seal configured to resist migration of water between the third roofing panel and the first roofing panel or the second roofing panel.

14. The roofing system of claim 13 , wherein each of the first and second connectors comprises a pair of flanges and a projection located between the flanges, and wherein the first roofing panel and the second roofing panel are received and engaged between opposing flanges of the first roofing panel and the second roofing panel with the projection at least partially received along a joint defined between the first roofing panel and the second roofing panel.

15. The roofing system of claim 13 , wherein the second connector is at least partially secured to the upper surface of the first roofing panel and to the upper surface of the second roofing panel with a sealant.

16. The roofing system of claim 13 , further comprising an adhesive applied between the overlap portion and the third roofing panel and configured to secure the overlap portion upper surface of the third roofing panel.

17. The roofing system of claim 13 , wherein each of the roofing panels comprises a core; wherein the core comprises polyisocyanurate, polystyrene, PVC, polyethylene, polyamide, phenolic material, or a combination thereof.

18. The roofing system of claim 17 , further comprising one or more layers overlying the upper surface of th

Assignees

• Bmic Llc

Inventors

• Svec James A

Classifications

• E04D3/352

  at least one insulating layer being located between non-insulating layers, e.g. double skin slabs or sheets · CPC title

• E04D3/35 Primary

  Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation {(self-supporting roofing slabs laminated with layers of insulating material E04B7/22; insulating devices or arrangements in the roof covering E04D13/16; connecting, fastening of double roof covering E04D3/3608)} · CPC title

• E04D3/362 Primary

  by locking the edge of one slab or sheet within the profiled marginal portion of the adjacent slab or sheet, e.g. using separate connecting elements · CPC title

• E04D3/366

  by closing the space between the slabs or sheets by gutters, bulges, or bridging elements, e.g. strips · CPC title

• E04D2003/3615

  Separate fastening elements fixed to the roof structure and consisting of parts permitting relative movement to each other, e.g. for thermal expansion · CPC title