Patent Application
20070028556
The present invention relates generally to roofing systems, and more particularly to a new and improved system for securing a plurality of slabs of insulation to the under-lying roof decking substructure by means of a plurality of batten strips, batten straps, batten bars, or the like, wherein the plurality of slabs of insulation are disposed within a grid-type arrangement comprising a plurality of horizontally or transversely oriented rows of the slabs of insulation and a plurality of vertically or longitudinally oriented columns of the slabs of insulation, wherein alternative columns of the slabs of insulation are preferably longitudinally offset with respect to the columns of the slabs of insulation which are interposed between the alternative columns of the slabs of insulation so as to effectively stagger adjacent or abutting slabs of insulation with respect to each other for enhancing wind uplift resistance properties, and wherein further, the plurality of batten strips, batten bars, batten straps, or the like, are oriented transversely across the adjacent, abutting columns of the slabs of insulation so as to permit each one of the plurality of transversely oriented batten strips, batten straps, batten bars, or the like, to fixedly secure the plurality of slabs of insulation which are effectively disposed within each transversely oriented row of the slabs of insulation.
Roofing battens, in the form of roofing strips, roofing straps, roofing bars, or the like, are of course well-known in the art and industry and are widely used for securing flexible, thermoplastic roofing sheets or environmental membranes to underlying roof decking substructures in order to protect the same from weather or environmental conditions. The roofing battens may be fabricated from any one of several different materials, such as, for example, metal, wood, thermoplastic, or the like, and may be provided with pre-punched holes or apertures for accommodating mechanical fasteners, such as, for example, roofing screws, which are passed through the apertures or holes formed within the roofing battens so as to in fact secure the roofing battens, and therefore the flexible, thermoplastic roofing sheets or environmental membranes, to the underlying roofing substructures. A thermoplastic or polymeric material having particular utility for fabricating a roofing batten is disclosed within U.S. Pat. No. 4,963,430 which issued to Kish et al. on Oct. 16, 1990, wherein the polymeric material from which the roofing batten is fabricated comprises a combination of PET, or polyethylene terephthalate, and a polyolefin, such as, for example, polypropylene. Still further, other thermoplastic roofing battens are likewise disclosed within U.S. Pat. No. 5,711,116 which issued to Hasan on Jan. 27, 1998, U.S. Pat. No. 5,469,671 which issued to Rathgeber et al. on Nov. 28, 1995, U.S. Pat. 5,349,804 which issued to Van Erden et al. on Sep. 27, 1994, U.S. Pat. 5,319,908 which issued to Van Erden et al. on Jun. 14, 1994, U.S. Pat. No. 5,309,685 which issued to Rathgeber et al. on May 10, 1994, U.S. Pat. No. 5,242,736 which issued to Van Erden et al. on Sep. 7, 1993, U.S. Pat. No. 5,161,342 which issued to Hasan et al. on Nov. 10, 1992, U.S. Pat. No. 4,736,562 which issued to Kelly on Apr. 12, 1988, U.S. Pat. No. 4,718,211 which issued to Russell et al. on Jan. 12, 1988, and U.S. Pat. No. 4,445,306 which issued to Schauffele on May 1, 1984.
It is noted, however, that despite the fact that such roofing battens are well-known, and that they have enjoyed widespread usage in connection with securing such flexible, thermoplastic roofing sheets or environmental membranes to underlying roof decking substructures in order to protect the same from weather or environmental conditions, such roofing battens have not been used heretofore in connection with securing slabs of insulation to the underlying roof decking substructures. To the contrary, the slabs of insulation have heretofore been secured to the underlying roof decking substructures by other means. One means or method for securing the slabs of insulation to the underlying roof decking substructure has comprised the use of suitable adhesives, however, due, for example, to the variance and severity of weather and environmental conditions, that is, for example, large temperature differentials as well as extreme wind conditions, the various adhesives could not always reliably maintain the slabs of insulation secured to the underlying roof decking substructures.
Another means or method of securing the slabs of insulation to the underlying roof decking substructure comprised the use of roofing plates fabricated from steel or another metal, however, as can readily be appreciated, the installation of the individual roofing plates is very time-consuming and tedious to operator personnel. In addition, the fabrication costs involved in connection with the manufacture of such metal or steel roofing plates is quite considerable, as are the freight costs for shipping and transporting such metal or steel roofing plates due to the considerably large weight of the metal or steel roofing plates. Still further, it is noted when the aforenoted flexible, thermoplastic roofing sheets or environmental membranes are to be secured atop the underlying slabs of insulation in order to protect the same from weather and other environmental conditions, under-surface portions of the flexible, thermoplastic roofing sheets or environmental membranes are adhesively bonded to the metal or steel plates utilized to secure the slabs of insulation to the underlying substructures. It has been experienced, however, that the adhesive, utilized in conjunction with securing the flexible, thermoplastic roofing sheets or environmental membranes to the underlying slabs of insulation, does not always adhere well to the metal or steel roofing plates. Accordingly, under, for example, wind uplift conditions, the flexible, thermoplastic roofing sheets or environmental membranes tend to pull away or become separated from the steel or metal roofing plates which then places additional and abnormal stresses upon other regions of the flexible, thermoplastic roofing sheets or environmental membranes which tends to exacerbate failure of the flexible, thermoplastic roofing sheets or environmental membranes and the protection they normally provide for the underlying roof decking substructures against weather and environmental conditions.
A need therefore exists in the art for a new and improved roofing insulation fastening system wherein the slabs of insulation can assuredly be secured to the underlying substructures, wherein the means for assuredly securing the slabs of insulation to the underlying roof decking substructures does not comprise solely adhesive means which is unreliable, wherein the means for assuredly securing the slabs of insulation to the underlying roof decking substructure does not comprise steel or metal plates which entail a considerable amount of weight and are labor-intensive and costly to install, wherein the means for assuredly securing the slabs of insulation to the underlying roof decking substructures comprise batten strips, batten straps, or batten bars which are relatively light in weight, are economical to fabricate, and can easily and rapidly be installed, and wherein flexible, thermoplastic roofing sheets or environmental membranes can be securely bonded to the batten strips, batten straps, or batten bars, for assuredly securing the slabs of insulation to the underlying substructures, such that the roofing sheets or environmental membranes do not pull away or prematurely separate from the batten strips, batten straps, or batten bars so as not to jeopardize the protective properties of the roofing sheets or environmental membranes with respect to the underlying roof decking substructures.
The foregoing and other objectives are achieved in accordance with the teachings and principles of the present invention through the provision of a new and improved system for securing a plurality of slabs of insulation to the under-lying roof decking substructure by means of a plurality of batten strips, batten straps, batten bars, or the like, wherein the plurality of slabs of insulation are disposed within a grid-type arrangement comprising a plurality of horizontally or transversely oriented rows of the slabs of insulation and a plurality of vertically or longitudinally oriented columns of the slabs of insulation. Alternative columns of the slabs of insulation are preferably longitudinally offset with respect to the columns of the slabs of insulation which are interposed between the alternative columns of the slabs of insulation so as to effectively stagger adjacent or abutting slabs of insulation with respect to each other for enhancing wind uplift resistance properties. In addition, the plurality of batten strips, batten bars, batten straps, or the like, are oriented transversely across the adjacent, abutting columns of the slabs of insulation so as to permit each one of the plurality of transversely oriented batten strips, batten straps, batten bars, or the like, to fixedly secure the plurality of slabs of insulation which are effectively disposed within each transversely oriented row of the slabs of insulation.
Various other features and attendant advantages of the present invention will be more fully appreciated from the following detailed description when considered in connection with the accompanying drawings in which like reference characters designate like or corresponding parts throughout the several views, and wherein:
Referring now to the drawings, and more particularly to
The batten strip 10 has a width dimension W which is preferably within the range of 0.95-1.03 inches, and has a thickness dimension T which is preferably within the range of 0.026-0.033 inches. In addition, the batten strip 10 is preferably provided with a plurality of holes or apertures 12 which are pre-punched into the batten strip 10, and it is seen that the plurality of holes or apertures 12 are longitudinally spaced from each other, along the longitudinally extending axis 14 of the batten strip 10, by means of a distance L which is preferably within the range of 2.97-3.03 inches. In addition, each one of the pre-punched holes or apertures has a diametrical extent which is preferably within the range of 0.187-0.197 inches so as to accommodate suitable mechanical nail or screw fasteners, not shown. Accordingly, each one of the batten strips 10 may be fixedly secured atop the slabs of insulation so as to assuredly secure the slabs of insulation to the underlying roof decking substructure. Still further, it is to be noted that in addition to the use of the mechanical nail or screw fasteners, the undersurface portion of each one of the batten strips 10 may have a layer of adhesive disposed thereon.
With reference now being made to
Continuing further, it is additionally seen that the plurality of slabs of insulation 112 are disposed within a grid-type arrangement comprising a plurality of longitudinally spaced, horizontally or transversely oriented rows, as schematically indicated by means of the loci 118,120,122, and a plurality of laterally spaced, vertically or longitudinally oriented columns as schematically indicated by means of the loci 124,126,128. In connection with this grid-type arrangement of the plurality of slabs of insulation 112, it is noted further that while the oppositely disposed side edge portions 116,116 of adjacent slabs of insulation 112 disposed within all of the rows 118,120,122 defining each one of the columns 124,126,128 are respectively located along common, laterally or transversely spaced, vertically or longitudinally oriented loci 130,132, the slabs of insulation 112 disposed within, for example, alternative columns 124 and 128 are longitudinally offset with respect to those slabs of insulation 112 which are disposed within the alternative column 126 which is effectively interposed between the columns 124,128. In this manner, the oppositely disposed end edge portions 114,114 of adjacent slabs of insulation 112 that are disposed within the columns 124,128 are respectively located along common vertically or longitudinally spaced, horizontally or transversely oriented loci 134,136, whereas the oppositely disposed end edge portions 114,114 of adjacent slabs of insulation 112 that are disposed within the column 126 are respectively located along vertically or longitudinally spaced, horizontally or transversely oriented loci 138,140 which are vertically or longitudinally offset from, or with respect to, the horizontally or transversely oriented loci 134,136. This offset pattern or arrangement of the slabs of insulation 112 serves to reduce any tendency of the slabs of insulation 112 to become separated from the underlying roof decking substructure in a continuously propagated manner if the roofing structure should be subjected or exposed to extremely high wind uplift forces.
With reference continuing to be made to
The plurality of batten strips 10 are adapted to be deposited atop the plurality of slabs of insulation 112, and fixedly secured to the underlying roof decking substructure, by means of a standup applicator tool, which is the subject of copending United States Patent Application which is entitled, ______, which was filed on in the name of Riaz Hasan et al., and which has been assigned Ser. No. ______, whereby the standup applicator tool dispenses the plurality of batten strips 10 along the vertically or longitudinally spaced, horizontally or transversely oriented loci 142,144,146 and fixedly secures the same atop the plurality of slabs of insulation 112 by means of suitable fasteners which are inserted through the prepunched holes or apertures 12. It may therefore be appreciated that the application of the plurality of batten strips 10 onto the slabs of insulation 112, and the fixation of the plurality of batten strips 10 to the underlying roof decking substructure is substantially faster, easier, and less fatiguing to operator personnel than the conventional or prior art technique of depositing a plurality of individual insulation plates onto the slabs of insulation and subsequently securing each one of the individual insulation plates to the underlying roof decking substructure.
In connection with the dispensing and application or fixation of the plurality of batten strips 10 onto the upper surface portions of the plurality of slabs of insulation 112, it has been noted that in addition to the insertion of the mechanical nail or screw fasteners through the prepunched holes or apertures 12 formed within the batten strips 10 so as be fixedly embedded within the underlying roof decking substructure, the under-surface portion of each one of the batten strips 10 may also have a layer of adhesive disposed thereon. Still yet further, it is noted that when the thermoplastic sheets or environmental membranes are to be secured atop the slabs of insulation 112, the batten strips, similar to those as disclosed within the aforenoted patents which issued to Hasan, Hasan et al., Van Erden et al., Rathgeber et al., Kelly, Russell et al., and Schauffele, may be secured both by mechanical fasteners and adhesives. Therefore, when the adhesives, disposed upon the undersurface portions of the batten strips being used to secure the thermoplastic sheets or environmental membranes atop the slabs of insulation 112, are adhesively bonded to the upper surface portions of the batten strips 10 being utilized to fixedly secure the slabs of insulation 112 to the underlying roof decking substructure, the fact that the batten strips 10 are fabricated from a suitable one of the aforenoted thermoplastic materials, the adhesives, disposed upon the undersurface portions of the batten strips being used to secure the thermoplastic sheets or environmental membranes atop the slabs of insulation 112, will more assuredly bond with, and remain bonded to, the batten strips 10 than with respect to, or as compared with, the metal or steel plates conventionally or heretofore used for fixedly securing slabs of insulation to the underlying roof decking substructure.
Thus, it may be seen that in accordance with the principles and teachings of the present invention, there has been developed and disclosed a new and improved system for securing a plurality of slabs of insulation to the underlying roof decking substructure by means of a plurality of batten strips, batten straps, batten bars, or the like, wherein the plurality of slabs of insulation are disposed within a grid-type arrangement comprising a plurality of horizontally or transversely oriented rows of the slabs of insulation and a plurality of vertically or longitudinally oriented columns of the slabs of insulation. Alternative columns of the slabs of insulation are preferably longitudinally offset with respect to the columns of the slabs of insulation which are interposed between the alternative columns of the slabs of insulation so as to effectively stagger adjacent or abutting slabs of insulation with respect to each other for enhancing wind uplift resistance properties. In addition, the plurality of batten strips, batten bars, batten straps, or the like, are oriented transversely across the adjacent, abutting columns of the slabs of insulation so as to permit each one of the plurality of transversely oriented batten strips, batten straps, batten bars, or the like, to extend across, span, or traverse the adjacent slabs of insulation so as to fixedly secure the plurality of slabs of insulation which are effectively disposed within each transversely oriented row of the slabs of insulation.
Obviously, many variations and modifications of the present invention are possible in light of the above teachings. For example, while it has been noted that the batten strips 10 extend across or traverse the mating or abutting side edge portions 116,116 defined between adjacent slabs of insulation 112 so as to be disposed substantially perpendicular to the longitudinally extending seamed edge portions defined between adjacent or mated slabs of insulation 112, it is also possible that the batten strips 10 extend across or traverse the mating or abutting end edge portions 114,114 defined between adjacent slabs of insulation 112 so as to be disposed substantially perpendicular to the laterally or transversely extending seamed end edge portions 114,114 defined between adjacent or mated slabs of insulation 112. If this is the case, then it is also to be noted that the batten strips 10 will be disposed at horizontally or transversely spaced positions which are located at an intermediate point between the oppositely disposed, mated side edge portions 116,116 of the slabs of insulation 112. It is therefore to be understood that within the scope of the appended claims, the present invention may be practiced otherwise than as specifically described herein.
