FLUTE FILLER

Abstract

A flute filler for a standing seam metal roof having a plurality of ribs and having valleys therebetween comprising is provided. The flute filler comprises a sheet having a plurality of planks secured thereto. The planks are arranged to be side by side at spaced intervals such that each plank is adapted to be disposed in a valley and the sheet overlies the planks when the flute filler is situated on the roof. A cover board and a roofing membrane may be disposed over the sheet of the flute filler. In order to situate the flute filler on the roof, the planks are placed in a valley of the standing seam roof which can be accomplished by unrolling a rolled flute filler.

Description

FIELD OF THE INVENTION

The present invention relates generally to a flute filler The flute filler may be rollable and may be used in connection with metal roofing.

BACKGROUND OF THE INVENTION

Flute fillers are often used when installing new roofing over an existing metal roof having standing seams to retrofit the roof. The standing seams, also referred to as ribs, on a metal roof are typically spaced apart at consistent intervals. A flute or valley is the area between adjacent ribs. Flute fillers may be used to provide either or both a mechanism to fill the valley between adjacent ribs seams and to provide insulation for the new roof. Current flute fillers typically comprise individual planks of an insulative material, such as for example expanded polystyrene, which are relatively light in weight. The planks are individually placed in the flute or valley on a metal roof between adjacent ribs. It is common for the planks to come in standard lengths, such as for example 8 feet. The width of the plank is selected based upon the space between adjacent ribs. Once the individual planks are situated, a cover board is typically placed over the planks and secured to the exiting metal roof to maintain the planks in their respective flutes. The cover board provides a relatively level substrate for receiving a weatherproof cover, such as a PVC (polyvinyl chloride) roofing membrane, a TPO (thermoplastic polyolefin) roofing membrane or an EPDM (ethylene propylene diene terpolymer) roofing membrane or any other membrane as are known in the art.

One issue with the installation of current flute fillers arises because each plank must be individually positioned between adjacent ribs. Typically, the planks are not secured directly to the metal roof, and instead are free to move within the valley. Each plank is relatively light in weight and is susceptible to movement as a result of wind or inadvertent movement such as by being kicked. Because several planks must be individually positioned prior to being covered with the cover board and the planks are not otherwise secured to the existing metal roof, the planks can be moved out from the valley, particularly on a windy day, before a cover board can be placed over them. Often times, weights are used to hold the planks in place until the cover board can be positioned and secured. The positioning of planks individually as well as any need to place weights to weigh down the individual planks results in a relatively longer time to retrofit the roof.

It would be desirable to provide a flute filler that reduces the time needed to place the planks or reduces the need to weigh down the planks during installation. Such a flute filler would allow for relatively faster roof installation times over the use of current flute fillers.

SUMMARY OF THE INVENTION

According to an embodiment, there is provided a flute filler. The flute filler comprises a plurality of planks secured to a sheet. Each plank is secured to a sheet and the planks are spaced from one another.

According to an embodiment, there is provided a flute filler for a standing seam metal roof having a plurality of ribs and having valleys therebetween comprising. The flute filler comprises a sheet having a plurality of planks secured thereto. The planks are arranged to be side by side at spaced intervals such that each plank is disposed in a valley and the sheets overly the planks. The system further comprises a membrane disposed over the sheet of the flute filler.

According to an embodiment, there is provided a method of filling flutes in a standing seam roof having ribs and valleys. The method comprises the step of providing a flute filler comprising a sheet and a plurality of planks secured on the sheet. The method further comprises the step of placing the plurality of planks in the valleys of the standing seam roof wherein the sheet is disposed over the planks and the standing seam roof while the planks are placed in the valleys.

Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

FIG. 1 is a perspective view of an embodiment of a flute filler;

FIG. 2 is a top view of an embodiment of a flute filler;

FIG. 3A is an end view of an embodiment of a flute filler;

FIG. 3B is an exploded view of a section of the embodiment of FIG. 3A;

FIG. 4A is an end view of an embodiment of a flute filler;

FIG. 4B is an exploded view of a section of the embodiment of FIG. 4A;

FIG. 5 is an embodiment of a flute filler in a roll; and

FIG. 6 is an embodiment of a flute filler having a cover board and roofing membrane thereover.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the disclosed embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or its uses.

An embodiment of a flute filler is generally shown at 10 in the Figures. The flute filler 10 comprises a sheet 12 and a plurality of planks 14, 14′. The sheet 12 can comprise any material to which the planks 14, 14′ may be secured. In one embodiment, the sheet 12 may comprise a vapor barrier, such as by way of example only, Duro-Last® Vapor Barrier available from Duro-Last, a division of Holcim Solutions and Products US, LLC located in Saginaw MI. In another embodiment, the sheet 12 may comprise a separation slip sheet, such as by way of example only Duro-Last® Duro-Blue Separation Slip Sheet also available from Duro-Last, a division of Holcim Solutions and Products US, LLC located in Saginaw MI. It will be appreciated that any suitable material may be used for the sheet 12. The sheet 12 is preferably flexible and can be rolled, as shown in FIG. 5. It will be appreciated, however, that the sheet 12 may be rigid or semi-rigid in some embodiments.

A standing seam roof is generally shown at 16. The standing seam roof 16 comprises a plurality of ribs 18. The standing seam roof 16 also comprises a plurality of valleys 20. The embodiments depicted in the Figures show that the ribs 18 are generally V-shaped and extend upwardly from the valleys 20. The rib 18 has a wider portion that is adjacent the valley 20 at the lower portion of the roof 16. The rib 18 narrows as it extends upwardly from the wider portion. The rib 18 may include a generally flat portion 19 spaced from the lower portion of the rib 18 as best seen in FIGS. 3B and 4B. While an embodiment of the rib 18 is shown, it will be appreciated that the ribs 18 may comprise any shape.

As best seen in FIGS. 3A and 3B, the planks 14 are arranged side-by-side in a spaced relationship. The planks 14 are adapted to be placed and fit into the valleys 20 between adjacent ribs 18 on the roof 16. The planks 14 may have any desired shape. In an embodiment as shown in FIGS. 3A and 3B, the planks 14 may have straight side edges so as to form a rectangular cross-section. This type of plank 14 may be referred to as square cut. While it will be appreciated that the planks 14 may take any dimensions that are sized to fit in the valleys 20 between adjacent ribs 18, in some embodiments, the planks 14 are between ¾ of an inch to two inches thick, 6 inches to 24 inches in width and 4 feet or 8 feet in length.

In another embodiment, as best seen in FIGS. 4A and 4B, the planks 14′ may have tapered side edges 24 to as to form a trapezoidal cross section. This type of plank 14′ may be referred to as taper cut. The planks 14′ may take any dimensions that are sized to fit in the valleys 20 between adjacent ribs 18. It will be appreciated that the side edges of the flutes 14, 14′ may take any desired configuration that fits in the valleys 20 between adjacent ribs 18. As with the planks 14, the planks 14′ in some embodiments are between ¾ of an inch to two inches thick, 6 inches to 24 inches in width and 4 feet or 8 feet in length.

The thickness of the planks 14, 14′ can vary as desired. The planks 14, 14′ may fill most of the valley 20 or only a portion of the valley 20. For example, the thickness of the plank 14, 14′ may be equal or nearly equal to the distance from the valley 20 to the height of the rib 18. In other embodiments, the thickness of the plank 14, 14′ may be more or less than the height of the rib 18, depending on the desired thickness dimension. Similarly, the width of the plank 14, 14′ may be nearly coextensive with the width of the valley 20 between adjacent ribs 18 or may be only a portion of the width of the valley 20 between adjacent ribs 18. In an embodiment, the planks 14, 14′ extend to be substantially even with the flat portions 19 of adjacent ribs 18. In certain embodiments, the placement of the planks 14, 14′ results in a flat or substantially flat uniform surface over which to place other roofing elements, such as cover boards 26 and roofing membranes 34.

The planks 14, 14′ preferably comprise an insulation material. By way of example, the planks 14, 14′ may comprise polystyrene or isocyanate insulation material, each of which may be foamed as are known in the industry. Any suitable material, however, may be used for the planks 14, 14′

As best seen in FIG. 5, the planks 14 are secured to the sheet 12 and the sheet 12 having the planks 14 thereon can be rolled. The planks 14 may be adhered to the sheet 12 using any suitable method. In one embodiment, an adhesive is used to secure the planks 14 to the sheet 12. In another embodiment, the planks 14 may be secured to the sheet 12 by using double sided tape. As explained above, the planks 14 are preferably placed side by side at regular or consistent spaced intervals in an embodiment so as to match the valleys 20 in the roof 16 onto which the flute filler 10 is to be installed. The rolled material, sheet 12 and planks 14, can have any suitable length after it is unrolled. That is, a continuous roll of a suitable length of the sheet 12 having the planks 14 thereon is provided. By way of example, the length of the flute filler 10 when unrolled may be 100 feet. Further, by way of example, one embodiment of the flute filler 10 may comprise a roll that, when unrolled, is 8 feet in width and 100 feet in length. FIG. 5 shows the square cut plank 14. It will be appreciated that the plank 14 can take any configuration, including a taper cut plank 14′ as described above.

The planks 14, 14′ may not extend to the edge of the sheet 12. That is, in some embodiments the sheets 12 extend beyond the planks 14, 14′ to create an overhang. In this manner adjacent sheets 12 having the planks 14, 14′ thereon may overlap to provide continuity of the sheet. In an embodiment, adjacent sheets 12 overlap so as to allow the sheet 12, e.g., the slip sheet or vapor barrier to be continuous and minimize or eliminate any gaps between adjacent sheets 12. As shown in FIGS. 1 and 2, the sheet 12 extends beyond the planks 14, 14′ in two directions, namely beyond opposite end edges of adjacent planks 14, 14′ and beyond the side edges of the first and last planks 14, 14′.

It will be appreciated that the sheet 12 may extend beyond only one end edge of adjacent planks 14, 14′. That is, each plank 14, 14′ may be secured to the sheet 12 such that one end edge of the plank 14, 14′ is at one of the side edges of the sheet 12 and the plank 14, 14′ extends toward the other of the side edges of the sheet 12, but not completely to the side edge such that the sheet 12 overhangs the other of the end edges of the planks 14, 14′.

Similarly, the sheet 12 may extend beyond only one side edge of the first or last planks 14, 14′. That is, one of the planks 14, 14′ is positioned such that one side edge of the plank 14, 14′ is at one of the end edges of the sheet 12 and another plank 14, 14′ is positioned such that one side edge of the plank 14, 14′ is spaced from the other of the end edges of the sheet 12 such that the sheet 12 overhangs the side edge of the other of the planks 14, 14′.

In other embodiments, (not shown) the sheet 12 may not extend beyond the end edges of adjacent planks 14, 14′ or beyond, the side edges of the first and last planks 14, 14′.

As best seen in FIGS. 3B, 4B and 6, one or more cover boards 26 may be placed over the flute filler 10. The cover boards 26 may be secured to the metal roof 16 using suitable fasteners 28. The fasteners 28 may pass through the cover boards 26 and the sheet 12 and be secured to the flat portions 19 of ribs 18. In an embodiment, the fasteners 28 may include screws 30 and plates 32. The plates 32 may be load distribution plates 32 as are known in the industry. It will be appreciated that any suitable fastener may be used to secure the flute filler 10 or the flute filler 10 and cover board 26 to the roof 16. Further, it will be appreciated that the fasteners 28 may be secured to any suitable portion on the roof 16 and in other embodiments (not shown) the fasteners 28 may be secured to locations on the roof 16 other than the flat portions 19 of ribs 18.

As best seen in FIG. 6, a suitable roofing membrane 34 may be placed over the cover boards 26. Example of suitable roofing membranes PVC (polyvinyl chloride) roofing membrane, TPO (thermoplastic polyolefin) roofing membrane or EPDM (ethylene propylene diene terpolymer) roofing membrane 34 or any other membrane as are known in the art. It will be appreciated that the roofing membrane may be waterproof. In an embodiment, the fasteners 28 are also used to secure the roofing membrane 34 to the metal roof 16. The roofing membrane 34 may be connected to the metal roof 16 using the fasteners 28 along edges thereof as is known in the art. It will be appreciated that the roofing membrane 34 may be connected to the metal roof 16 in any suitable fashion.

The flute filler 10 may be used to retrofit a standing seam metal roof 16. To accomplish this, a flute filler 10 is obtained which comprises a plurality of planks 14, 14′ secured to a sheet 12. The sheet 12, having the planks 14, 14′ connected thereto may be rolled, FIG. 5, for ease of shipping, handling and installation. The flute filler 10 roll may then be placed on a metal roof 16 and is unrolled so as to situate the planks 14, 14′ in the valleys 20 between adjacent ribs 18 in the metal roof 16. Because the spacing of the ribs 18 and valleys 20 is consistent, and the planks 14, 14′ are also consistently spaced, the planks 14, 14′ will align with the valleys 20 when the flute filler 10 is unrolled, which may result in less time needed for installation of the flute filler. It will be appreciated that multiple flute fillers 10 may be required to retrofit an entire roof 16. Each flute filler 10 may be unrolled in a manner such that the sheets 12 of adjacent flute fillers 10 may overlap and the planks 14, 14′ on adjacent flute fillers 10 may be disposed within the valley 20 in close proximity to one another. When unrolled, the flute fillers 10 are less susceptible to movement than if single planks 14, 14′ were are installed. That is, the flute filler 10 reduces, or in instances eliminates, movement of the planks 14, 14′ out of the valleys 20 such as by movement due to wind, physical force, such as kicking or the like. Cover boards 26 may be placed over the flute filler 10 and particularly the sheets 12 thereof. A roofing membrane 34 may be placed over the cover board 26. The roofing membrane 34, cover boards 26 and flute filler 10 may be secured to the metal roof 16 using suitable fasteners 28, or other fastening technique.

Claims

1. A flute filler comprising: a plurality of planks; anda sheetwherein the planks are secured to a sheet.

2. A flute filler as set forth in claim 1 wherein the plurality of planks are arranged side by side and spaced from one another.

3. A flute filler as set forth in claim 2 wherein the spacing between adjacent planks is at a regular interval.

4. A flute filler as set forth in claim 2 wherein the planks comprise an insulating material.

5. A flute filler as set forth in claim 4 wherein the planks comprise polystyrene or isocyanate insulating material.

6. A flute filler as set forth in claim 2 wherein the planks are secured to the sheet by an adhesive.

7. A flute filler as set forth in claim 2 wherein the planks are secured to the sheet with double sided tape.

8. A flute filler as set forth in claim 2 wherein the sheet is rectangular and has two end edges and two side edges.

9. A flute filler as set forth in claim 2 wherein each plank has a pair of end edges and a pair of sided edges.

10. A flute filler as set forth in claim 9 wherein each plank is secured to the sheet such that one end edge of the plank is at one of the side edges of the sheet and the plank extends toward the other of the side edges of the sheet such that the sheet overhangs the other of the end edges of the planks.

11. A flute filler as set forth in claim 10 wherein at least one plank is positioned such that one side edge of the plank is at one of the end edges of the sheet and another plank is positioned such that one side edge of the plank is spaced from the other of the end edges of the barrier layer such that the sheet overhangs the side edge of the other of the planks.

12. A flute filler as set forth in claim 2 wherein the plank is configured to be positioned between adjacent standing seams of a standing seam roof.

13. A flute filler as set forth in claim 2 wherein each plank has a rectangular cross section.

14. A flute filler as set forth in claim 2 wherein the flute filler can be rolled.

15. A flute filler as set forth in claim 2 wherein each plank has a trapezoidal cross section.

16. A flute filler for a standing seam metal roof having a plurality of ribs and having valleys therebetween comprising: a sheet having a plurality of planks secured thereto, the planks arranged to be side by side at spaced intervals such that each plank is disposed in a valley and the sheets overlies the planks; anda roofing membrane disposed over the sheet of the flute filler.

17. A flute filler as set forth in claim 16 further comprising a cover board disposed between the sheet and the roofing membrane.

18. A flute filler as set forth in claim 17 comprising a plurality of flute fillers and wherein the sheet of each flute filler is rectangular and has two end edges and two side edges.

19. A flute filler system as set forth in claim 18 wherein each plank has a pair of end edges and a pair of sided edges.

20. A flute filler as set forth in claim 19 wherein each plank is positioned such that one end edge of the plank is at one of the side edges of the sheet and the plank extends toward the other of the side edges of the sheet such that the sheet overhangs the other of the end edges of the planks.

21. A flute filler as set forth in claim 16 wherein the spacing between adjacent planks is uniform.

22. A flute filler as set forth in claim 16 wherein each plank comprises an insulating material.

23. A flute filler as set forth in claim 16 wherein each plank is positioned such that one end edge of the plank is at one of the side edges of the sheet and the plank extends toward the other of the side edges of the sheet such that the sheet overhangs the other of the end edges of the planks.

24. A flute filler as set forth in claim 16 wherein at least one plank is positioned such that one side edge of the plank is at one of the end edges of the sheet and another plank is positioned such that one side edge of the plank is spaced from the other of the end edges of the barrier layer such that the sheet overhangs the side edge of the other of the planks.

25. A method of filling flutes in a standing seam roof having ribs and valleys comprising the steps of: providing a flute filler comprising a sheet and a plurality of planks secured on the sheet;placing the plurality of planks in the valleys of the standing seam roof wherein the sheet is disposed over the planks and the standing seam roof while the planks are placed in the flutes.

26. A method as set forth in claim 25 further wherein the flute filler is rolled as provided and then unrolled so as to place the plurality of planks in the valleys of the standing seam roof between adjacent ribs.