Patent Application
20190106882
The present disclosure relates to a prefabricated module for a pitched roof element comprising a frame made of at least two first beams being arranged in a distance and running parallel to each other and two second beams running rectangular to the first beams and being connected to the ends of the first beams forming a compartment into which a first layer of an insulation is inserted. Furthermore, the present disclosure relates to a pitched roof element for a building roof made of at least two modules, each comprising a frame made of at least first beams being arranged in a distance and running parallel to each other and two second beams running rectangular to the first beams and being connected to the ends of the first beams forming a compartment into which a first layer of an insulation is inserted.
This section provides background information related to the present disclosure which is not necessarily prior art.
Generally it is known to provide an insulating roof support assembly for a roof structure comprising a plurality of roof elongated rafters spaced apart in a predetermined distance with insulation bars there between. On top of such roof support assembly roof tiles or other types of roof claddings are mounted.
It is also known to provide solutions for new-built buildings as well as for the refurbishment sector in order to deal with the constantly increasing requirements being specified in respect to thermal insulation respectively energy savings.
Nevertheless, providing a roof to a building assembly, especially a pitched roof is always time consuming, as roofers have to do a lot of working steps until the roof is finished. All the steps have to be done on the construction area by carpenters and roofers. In case of a pitched roof this has to be done on a sloped construction assembly.
First of all, the roof structures, typically of timber have to be installed on top of the top floor of the building assembly. Normally such roof structures of timber consist of roof beams, rafters, collar beams etc. After finishing the roof structures of timber battens, mainly slating and tiling battens have to be fixed on top of the rafters before for example tiles are fixed to the battens to finally weather protect the building roof construction. Insulation material has to be installed in-between the rafters and/or the battens to fulfill requirements with respect to thermal insulation. As all these works have to be done on the building site all the works are dependent on the weather conditions. In case of bad weather conditions these works can be interrupted and finalization of the whole project might be postponed.
In WO 2009/153232 there is disclosed an insulating building system for an external building structure, such as a wall or a roof, or an internal building structure of the above-mentioned kind. This building assembly comprises a top and a bottom profile with a plurality of joining profiles between the top and bottom frame profiles. The joining profiles have a first and second side surfaces which are abutted by the contact sides of adjacent insulating panels on each side of said joining profiles, wherein the profile contact sides of the insulation panels are provided with a shape matching the profile side surfaces of the joining profiles such that the insulation panels are retained between two profiles. The insulation panels thereby support the joining profiles and provide stability and strength to the wall structure and prevent the joining profiles from buckling.
However, these known insulating building systems are often complex, difficult to install on a roof, and furthermore there are increasing demands for extra thermal insulation in roof constructions in order to provide a comprehensive thermal building insulation.
This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
It is therefore an object of the present disclosure to provide a prefabricated module for a pitched roof element which can be easily installed on a building assembly whereby the installment can be made in short time with a high degree of safety for the installer, and whereby the roof element finally has thermal insulation characteristics fulfilling the increasing demands in order to provide a comprehensive thermal building insulation.
This object is achieved by a prefabricated module comprising a frame made of at least two first beams, typically wooden rafters, being arranged in a distance and running parallel to each other and two second beams running rectangular to the first beams and being connected to the ends of the first beams forming a compartment into which a first layer of an insulation made of mineral fibres and a binding agent is inserted. The prefabricated module further comprising a second layer of the insulation being arranged above the first layer of the insulation, covering the frame and being fixed at least to the first and/or the second beams, whereby the second layer of the insulation has a higher bulk density than the first layer of the insulation and whereby the first beams have a length being at least equal to an extension of the roof between a ridge purlin and an inferior purlin. It should be pointed out that in the context of the present disclosure insulation made of mineral fibres and a binding agent are to be understood as insulating products being rendered by and in accordance with European Standard EN 13162.
A major advantage of such a prefabricated module is that only this module has to be handled to build up a first half of a pitched roof element spanning from the ridge purlin to the inferior purlin. The module has already perfect thermal insulation characteristics as it contains two layers of insulation material, especially made of mineral fibres and a binding agent. Furthermore, the second layer of the insulation has a high bulk density and improved mechanical resistance so that workers can walk and stand on the insulation without risking to step through the insulation and getting hurt. This ensures a high degree of safety for the craftsmen during the installation.
Furthermore, the object is achieved by a pitched roof element made of two modules, each comprising a frame made of at least two first beams being arranged in a distance and running parallel to each other and two second beams running rectangular to the first beams and being connected to the ends of the first beams forming a compartment into which a first layer of an insulation made of mineral fibres and a binding agent is inserted, whereby the modules are connected pivotably to each other via a hinge being connected to a second beam of each frame so that the frames can be moved from a position in which the first beams of the frames are running parallel to each other and resting on each other to a position in which the frames enclose an angle between the first beams in the area of the hinge being at least equal to an angle between two halves of the roof forming a V-shaped adjustment.
Such a pitched roof element made of two modules has the big advantage that in principle the whole roof can be prefabricated. Depending on the width of a building to be covered with said roof elements it might be one or more elements to be arranged adjacent to each other but the whole roof is prefabricated off-site. Such elements are easily transported as the two halves of the roof elements are pivotably connected to each other by a hinge. During transportation the whole roof can be enveloped in a foil as to protect it against weather conditions. On the construction area the roof elements can be lifted by a crane to the top of the building assembly after the two modules of the pitched roof element are moved into the V-shaped adjustment. The pitched roof element can be arranged on top of the building assembly, fixed to it and final steps to finish the roof as arranging a covering on top of the modules can be started. Such a pitched roof element is easy and fast to install which massively decreases the time of building for example family homes. A further aspect is the prefabrication of the pitched roofs as it consists of two prefabricated modules which can be prefabricated in the factory with all necessary facilities and under defined conditions.
According to a further embodiment of the prefabricated module the first beams and/or the second beams are connected to a board, e.g. a cladding board being arranged adjacent to the first layer of the insulation and/or in that a membrane is arranged adjacent to the second layer of the insulation. To use boards being arranged adjacent to the first layer of the insulations being connected to the first beams and/or the second beams provides the module with a higher stability and makes it more easy to install the first layer of insulation into the compartment as this compartment is then closed on one side already. The first layer of insulation is normally a web-like insulation material made of mineral fibres and a binding agent. Such insulation layer is typically optimized in respect to its thermal performance, i.e. with a relatively low bulk density of e.g. 20 to 40 kg/m3 and a declared thermal conductivity of about λD=0.030 to 0.035 W/(m*K). The insulation material is clamp fitted into the compartment which has the advantage that the insulation layer is in contact to all beams forming the compartment. Thermal bridges because of gaps are avoided.
Furthermore, a vapor permeable membrane is arranged adjacent to the second layer of the insulation. The membrane covers the top side of the second layer and may be fixed to the outsides of the beams. Fixing means, like e.g. nails, clamps, cramps etc. can be used. The membrane protects the insulation layers against water ingress and accumulation of humidity in the construction. It may to some extent also protect the insulation from damages caused by workers walking on it while arranging the roof covering on top of the modules.
In yet another embodiment of the disclosure the second layer of the insulation is a dual density board made of mineral fibres and a binding agent. Therefore, the second layer of insulation contains two layers of insulation material having different densities. The upper layer with the higher bulk density is arranged on the outside of the module which gives an improved protection against damages as described before. Furthermore, such a dual density board has improved thermal characteristics as the bottom layer with the lower bulk density has a lower U-value, thus enhanced thermal properties compared to the upper layer of the second layer of the insulation having a higher bulk density.
Preferably the second layer of the insulation has a bulk density of at least 80 kg/m3 and/or a declared thermal conductivity of at least λD=0.038 W/(m*K) and/or a high mechanical resistance indicated by a point load resistance of at least 120 kPa respectively 600 N per 50 cm2 at a deformation of 5 mm according to European Standard EN 12430. Such a second layer of insulation provides excellent thermal insulating properties and moreover has a high resistance against point load so that it is protected against damages by workers standing or walking on the insulation. For the same reason the second insulation layer provides for more safety during mounting of the pitched roof elements to a building roof and the subsequent finishing with either roof tiles or other coverings.
According to another preferred embodiment of the disclosure counter battens running parallel to the first beams are fixed to the first beams and/or second beams whereby the second layer of the insulation is arranged between the counter battens and the frame. The present disclosure in that respect provides for an additional major benefit due to the extraordinary mechanical resistance of the second layer, namely in that the high point load resistance serves for a solid surface or bedding for the counter battens. This, is particular beneficial in view of the accuracy to be achieved for the mounting of said battens in a plane. It is much easier to arrive at a plane roof surface and accurate result for the final covering.
Moreover, the use of a second layer of insulation bridging the space between the frame and the counter battens ensures a nearly thermal bridge-free construction which easily fulfills present demands in relation to the thermal insulation of buildings. By way of example reference is made to the national Dutch building regulations defining minimum requirements in the so-called “Bowbesluit”, e.g. table 5.1. For a roof construction which is subject to this disclosure e.g. a minimum RC-value of 6.0 (m2*K)/W is defined. Depending on the thicknesses of the insulation layers and the total construction, RC-values of 7.0 (m2*K)/W and higher can be achieved for the prefabricated modules respectively the pitched roof elements.
Thus, the elements according to the disclosure can also comply with e.g. the passive house demands according to recommendations by the German passive house institute (PHI), Darmstadt, as the roof construction can be provided with a U-value≤0.12 W/(m2*K), in particular as low as 0.1 W/(m2*K).
The modules will be prefabricated in total so that only the roof covering has to be installed after the module or the pitched roof element has been fixed to the building assembly. For this purpose it is of advantage to use tiling battens running parallel to the second beams, the ridge purlin and the inferior purlin being fixed to the counter battens.
A further advantageous module according to the disclosure is characterized in that at least a further beam is disposed between the outer first beams of the frame, whereby at least two compartments are provided between two beams and whereby the compartments have identical dimensions in length and/or width and/or depth. Such modules can be constructed with one, two, three or more compartments. Each compartment has a width according to the normally used webs made of mineral fibres and a binding agent being clamp fitted into the compartments. According to this as the compartments are constructed according to the usually used webs having a defined width modules of different width can be produced and used to build up pitched roofs of several lengths. Such modules can be used in a way of a construction kit giving the possibility of being combined top most of the length of roofs in the direction of the purlins as used especially in family homes. The modules forming one half of the pitched roof element can be arranged in different ways and connected via screws running through the first beams. To avoid thermal bridges thin layers of insulation material especially made of mineral fibres and a binding agent can be arranged between two first beams of neighbored modules.
Finally, the second layer of insulation has a thickness between 60 mm and 160 mm being thinner than the thickness of the frame and/or the first layer of the insulation having a thickness of at least 200 mm. These thicknesses may even further increase in order to meet future demands for thermal insulation and energy efficiency.
The pitched roof element according to the disclosure is advantageously developed in that each module comprises a second layer of insulation being arranged above the first layer of the insulation covering the frame and being fixed at least to the first and/or the second beams, whereby the second layer of the insulation has a higher bulk density than the first layer of the insulation and whereby the first beams have a length being at least equal to an extension of the roof between a ridge purlin and an inferior purlin. Furthermore, it is of advantage to have counter battens running parallel to the first beams and being fixed to the first beams and/or second beams whereby the second layer is arranged between the counter battens and the frame and second battens running parallel to the second beams, the ridge purlin and the inferior purlin being fixed to the counter battens. Such a roof is mainly prefabricated and ready to install on top of a building assembly whereby only the roof covering has to be arranged on top of the counter battens by workers. It may be of advantage to incorporate further insulation elements between these counter battens to increase the thermal insulation characteristics of the pitched roof element.
Finally, according to a further development of the roof both modules are provided with at least one fixing point to which an element to keep the modules in the V-shaped adjustment are fixable at least until the modules are fixed to a building. This element simplifies the installment of the prefabricated pitched roof element and it is of advantage to use two elements on both sides of the two modules just to stabilize the two halves of the roof in the V-shaped adjustment before putting it on the building assembly.
The before described disclosure relates especially to a pitched roof element having high insulation values, no thermal bridges and a vapor open construction. Furthermore, this roof according to the disclosure has characteristics of an air tight system with high acoustic performances. An exceptional fire resistance for the whole construction including the load-bearing parts is given so that installations, e.g. solar panels or the like can be installed above the rafters. The roof according to the disclosure has a high mechanical stability and it is therefore suitable for carrying such installations and has especially a suitable walkability even in the areas of the insulation layers without going the risk that the insulation is damaged. Furthermore, boards of mineral wool can be used as second insulation layer on top of the frame covering the frame and the first insulation layer. This second insulation layer can be fixed with nails to the frame which further reduces thermal bridges and which can be easily done by shooting the nails through the second layer of insulation into the beams of the frame.
The roof according to the disclosure is advantageous because insulation elements have a sufficient rigidity and good load-carrying capability in particular in a new-built situation, whilst at the same time being sufficient resilient so that any unevenness in the wooden rafters are avoided by using prefabricated modules having the rafters already included.
Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
In the following the disclosure is described in more details with reference to the accompanying drawings, in which:
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
Example embodiments will now be described more fully with reference to the accompanying drawings.
The modules 3 are connected via a hinge 4 being arranged in the area of a ridge purlin 5. Said hinge 4 allows the two modules 3 to be moved from a position in which the modules 3 are lying parallel to each other to a position shown in
From
It can be seen that the modules 3 span at least from the ridge purlin 5 to both inferior purlins 6.
It is evident that it is of advantage to use two of these elements 7 on both sides of the roof element 1, especially if the roof element 1 is lifted in total on top of the building assembly 2. In connection with smaller modules 3 one element 7 may be sufficient and especially in case of a roof according to
Two neighbored first beams 10 and the two second beams 11 being arranged on either side of the first beams 10 provide a compartment 12 of rectangular shape into which a first layer 13 of an insulation made of mineral wool, i.e. mineral fibres and a binding agent is inserted. The first layer 13 is clamp fitted into the compartment 12 which means that the first layer 13 has a width being a little bit larger than the distance between the parallel running first beams 10.
The thickness of the first layer 13 of the insulation corresponds to the height of the first beams 10 but it might be possible to use a compressible first layer 13 being a little bit thicker than the height of the first beams 10 and therefore the compartment 12 so that a total filling of the compartment 12 with insulation material is ensured.
The first beams 10 and the second beams 11 are connected to a board 14 closing the compartments 12 on one side of the frame 9. Beams 10, 11 and board 14 are made of wood.
The connection of the beams 10, 11 and the board 14 can be arranged by screws and/or nails and additionally by using an adhesive.
According to
It can be seen from
Finally, the module 3 according to
The membrane 17 is waterproof and protects the module 3, especially the insulation material but also wooden beams against water ingress which can cause damages to the insulation and/or the mechanical parts of the module 3. It can be seen that part of the membrane covers the outside of the first beams 10 and of course the membrane 17 can be arranged in a way that also the outer parts of the second beams 11 are covered by the membrane 17.
One main aspect of the module 3 shown in
The second layer 15 consists of mineral wool boards, especially made of stone wool and binding agent having a thickness of 60 mm resulting in a total height of the module 3 without the counter battens 19, 20 of 290 mm being the addition of the height of the second layer 15, the first layer 13 and the thickness of the cladding board 14 being 10 mm. The second layer 15 being made of dual density boards eliminates thermal bridges and makes it possible to stand on the whole surface of the module 3. The module 3 according to the disclosure establishes a safe vapor-open construction which can be easily handled as a prefabricated module or a prefabricated roof element 1 which decreases the time needed to build up a roof on a building assembly 2. Mineral wool provides for a very low value of water vapor diffusion resistance which may be assumed to be equal to μ=1. The insulation layer will thus ensure that the moisture being included in the construction may easily disappear without causing any harm. A construction as has been described above and as is further shown in
Furthermore, the second layer 15 provides a higher additional value in terms of acoustics and of course thermal accumulation and fire safety. The thermal performance of a construction, here the roof element 1 and the modules 3 is indicated by its thermal resistance or the Rc-value according to e.g. Dutch Standard NEN 1068 and will be at a minimum of 7.0 W/(m2*K). Depending on the thickness of the second layer 15 the thermal resistance can be in the range between 60 mm for Rc=7.0 W/(m2*K) via 100 mm for Rc=8.0 W/(m2*K) to 140 mm for Rc=9.0 W/(m2*K) or even higher.
Furthermore, it can be seen from
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
| Number | Date | Country | Kind |
|---|---|---|---|
| 16161965.5 | Mar 2016 | EP | regional |
This application is a National Stage of International Application No. PCT/EP2017/056122 filed on Mar. 15, 2017, and published in English as WO2017/162498 A1 on Sep. 28, 2017. This application claims the priority to European Patent Application No. 16161965.5, filed on Mar. 23, 2016. The entire disclosures of the above applications are incorporated herein by reference.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2017/056122 | 3/15/2017 | WO | 00 |
