Green roofing system including dimpled anchor layer

Abstract

A roofing panel includes a carrier comprising a web with an upper surface; a plurality of water retention compartments provided in the web and depending generally downwardly from the upper surface of the web; an anchor layer overlying at least a portion of the upper surface of the web, the anchor layer having an underside surface generally bearing against the upper surface of the web; and a plurality of dimples provided in the anchor layer, each of the dimples comprising a protruding portion extending generally downwardly from the underside surface of the anchor layer, each protruding portion adapted to nest at least partially within a respective one of the water retention compartments.

1 . A roofing panel comprising:
 a) a carrier comprising a web with an upper surface;   b) a plurality of water retention compartments provided in the web and depending generally downwardly from the upper surface of the web;   c) an anchor layer overlying at least a portion of the upper surface of the web, the anchor layer having an underside surface generally bearing against the upper surface of the web; and   d) a plurality of dimples provided on the anchor layer, each of the dimples comprising a protruding portion extending generally downwardly from the underside surface of the anchor layer, the protruding portions adapted to be received at least partially within respective ones of the water retention compartments.   
   
   
       2 . The roofing panel of  claim 1 , wherein the dimples are positioned on the anchor to correspond to positions of the water retention compartments on the web, such that the protruding portions of at least a first group of the dimples nest inside a first group of the water retention compartments. 
   
   
       3 . The roofing panel of  claim 2 , wherein the positions of the water retention compartments follow a repeating pattern. 
   
   
       4 . The roofing panel of  claim 1 , wherein the protruding portions are shaped to correspond to an interior surface of the water retention compartments in which the protruding portions are nested. 
   
   
       5 . The roofing panel of  claim 4 , wherein the protruding portions extend to a sufficient depth within the water retention compartments to generally abut a lower surface of the water retention compartments. 
   
   
       6 . The roofing panel of  claim 1 , wherein each of the dimples comprises a base and a sidewall extending from the underside of the anchor layer to the base. 
   
   
       7 . The roofing panel of  claim 6 , wherein the dimples are generally circular in shape when viewed from above, the dimples each having a diameter between 1 cm and 25 cm, and a depth between 0.1 cm and 10 cm. 
   
   
       8 . The roofing panel of  claim 6 , wherein each dimple has an interior defining a recess in a top surface of the anchor, the top surface disposed opposite the underside surface. 
   
   
       9 . The roofing panel of  claim 8  wherein each recess in the dimples defines a sump, and wherein the carrier further comprises drainage holes, the drainage holes being located away from the sump. 
   
   
       10 . The roofing panel of  claim 6 , wherein the anchor layer comprises intertwined fibers, and the sidewall of each of the dimples comprises a lower intertwined fiber density than other portions of the anchor layer. 
   
   
       11 . The roofing panel of  claim 10 , wherein the anchor layer further comprises pre-grown vegetation, the pre-grown vegetation being grown at a site remote from the site of installation of the roofing panel. 
   
   
       12 . A method of producing a roofing panel comprising the steps of:
 a) placing a blank anchor layer in a stamping machine, wherein the stamping machine comprises: a first plate comprising a plurality of male heads, and a second plate comprising a plurality of female wells, the male heads and female wells being aligned such that the male heads are receivable within the female wells, the blank anchor layer being placed between the first plate and the second plate; and   b) forming a plurality of dimples in the blank anchor layer by closing the first plate and the second plate together such that the male heads align with the female wells.   
   
   
       13 . The method of  claim 12 , further comprising the step of laying the blank anchor layer on an upper surface of a carrier, the carrier comprising a web, and a plurality of water retention compartments formed in the web, wherein a first group of the dimples nest inside a first group of the water retention compartments. 
   
   
       14 . The method of  claim 12 , wherein the step of forming the dimples includes pressing an underside of the blank anchor layer against the upper surface of the carrier. 
   
   
       15 . The method of  claim 12 , further comprising the step of placing an adhesive on at least one of an underside surface of the blank anchor layer and the upper surface of the carrier. 
   
   
       16 . The method of  claim 12 , further comprising the step of curing the adhesive. 
   
   
       17 . A roofing system comprising a plurality of roofing panels, each of the plurality of roofing panels comprising:
 a) a carrier comprising a web with an upper surface;   b) a plurality of water retention compartments provided in the web and depending generally downwardly from the upper surface;   c) an anchor layer overlying at least a portion of the upper surface of the web such that an underside of the anchor layer at least partially contacts the upper surface of the web; and   d) a plurality of dimples formed in the anchor layer, wherein each of the dimples comprises a protruding portion extending from an underside of the anchor layer, wherein at least one of the protruding portions nests inside at least one of the water retention compartments.   
   
   
       18 . The roofing system of  claim 17 , wherein the plurality of roofing panels further comprises:
 a) a first roofing panel with a first group of water retention compartments located laterally adjacent a first edge of the carrier of the first roofing panel;   b) a second roofing panel with a second group of water retention compartments located laterally adjacent a second edge of the carrier of the second roofing panel; and   wherein the first group of water retention compartments nests within the second group of water retention compartments.   
   
   
       19 . The roofing system of  claim 18 , wherein a first group of the dimples on the anchor layer of either the first roofing panel, or the second roofing panel, nest inside the first group of water retention compartments. 
   
   
       20 . The roofing system of  claim 19 , wherein the water retention compartments and the dimples have a repeating pattern to allow nesting of a first group of water retention compartments of a first roofing panel inside a second group of water retention compartments of a second roofing panel.