Roof system and method of fabrication and installation

Abstract

In a roof system having exceptional insulating value, high density polyurethane foam or extruded polystyrene is used to form molded panels of predetermined size, shape and ornamental configuration. A non-skid primer coat is applied to the top surfaces and sides of the panels at the time of manufacture. A fabric layer or polyester mesh may be embedded in the bottom of the molded foam panels to enhance adhesion characteristics. During installation, the panels are set in a layer of low rise foam adhesive that is applied to the underlying roof deck or other surface (e.g., plywood, concrete, roofing felts, or spray foam), thereby avoiding the use of penetrating fasteners while enhancing wind uplift resistance. The panels may include interlocking structure for side-by-side and/or overlapping installation. Edges of the foam panels that need to be cut for fitting at valleys, hips, ridges, etc. are repaired in the field using factory supplied fabric and coating. After complete installation of the panels, a final topcoat composition such as, but not limited to, acrylic epoxy, silicon, or polyurea is applied to seal the roof system and provide a select roof color and desired grade.

1 . A panel system for installation on an exterior surface of a building structure, said system comprising:
 a plurality of individual panels each of predetermined size, shape and configuration, and each of said plurality of panels including:
 a core molded with a foam composition into said predetermined size, shape and configuration; 
 a primer composition applied to at least a portion of exposed surfaces of said molded foam core, including a top surface and side surfaces, and said applied primer composition defining and outer shell to at least partially encapsulate said molded foam core; 
   a low rise foam adhesive composition applied as a layer over the exterior surface of the building structure for installation and bonding attachment of said plurality of individual panels in covering relation to the underlying layer of low rise foam adhesive and the exterior surface of the building structure; and   a top coat composition applied to said installed plurality of individual panels for coloring and sealing the installed panel system.   
   
   
       2 . The panel system according to  claim 1  wherein said foam composition is high density polyurethane foam. 
   
   
       3 . The panel system according to  claim 1  wherein said foam composition is polystyrene. 
   
   
       4 . The panel system according to  claim 1  wherein at least some of said plurality of individual panels include a fabric layer on a bottom side of said molded foam core for enhancing adhesion to said layer of low rise foam adhesive. 
   
   
       5 . The panel system according to  claim 1  wherein at least some of said plurality of individual panels include a mesh material on a bottom side of said molded foam core for enhancing adhesion to said layer of low rise foam adhesive. 
   
   
       6 . The panel system according to  claim 1  wherein said top coat composition is an acrylic epoxy. 
   
   
       7 . The panel system according to  claim 1  wherein said top coat composition is silicon. 
   
   
       8 . The panel system according to  claim 1  wherein said top coat composition is polyurea. 
   
   
       9 . The panel system according to  claim 1  further comprising:
 a layer of spray foam insulation applied over the exterior surface of the building structure and between said exterior surface and said layer of low rise foam adhesive composition.   
   
   
       10 . A method of fabrication and installation of a panel system on an exterior surface of a building structure, said method comprising the steps of:
 forming a plurality of individual panels of predetermined size, shape and configuration by first molding a core into said predetermined size, shape and configuration using a foam composition, and then applying a primer composition to at least a portion of exposed surfaces of said molded foam core, including a top surface and side surfaces of said molded foam core;   applying a layer of a low rise foam adhesive composition over the exterior surface of the building structure;   placing the plurality of individual panels on top of the layer of low rise foam adhesive composition and positioning the plurality of individual panels in covering relation to the underlying layer of low rise foam adhesive composition and the exterior surface of the building structure; and   applying a top coat composition of select color and grade to exposed surfaces of the plurality of individual panels for coloring and sealing the installed panel system.   
   
   
       11 . The method according to  claim 10  comprises the further steps of:
 cutting at least some of the plurality of individual panels prior to said step of placing the cut panels over said layer of low rise foam adhesive composition in order to fit said cut panels at edges, valleys, hips, ridges, wall junctions and other areas of the exterior surface of the building structure;   applying a primer composition to said cut panels to cover exposed areas of said molded foam core.   
   
   
       12 . The method according to  claim 11  wherein said step of applying said top coat composition is accomplished by spraying said top coat composition over the exposed surfaces of said plurality of individual panels of the installed panel system. 
   
   
       13 . The method according to  claim 12  wherein said foam composition of said molded foam core is a high density poly urethane foam composition. 
   
   
       14 . The method according to  claim 12  wherein said foam composition of said molded foam core is polystyrene. 
   
   
       15 . The method according to  claim 12  wherein said top coat composition is acrylic epoxy. 
   
   
       16 . The method according to  claim 12  wherein said top coat composition is silicon. 
   
   
       17 . The method according to  claim 12  wherein said top coat composition is polyurea. 
   
   
       18 . The method according to  claim 12  comprising the further step of:
 applying a layer of spray foam insulation over the exterior surface of the building structure prior to said step of applying said layer of low rise adhesive composition.