Roof panel

Abstract

A roof panel ( 1 ) for use in forming a low pitch or flat roof comprises a profiled inner liner or decking sheet ( 2 ), an outer waterproof membrane ( 3 ) and a body ( 4 ) of insulation between the inner liner ( 2 ) and outer membrane ( 3 ). The membrane liner sheet ( 3 ) has a backing such as a fleece or scrim to aid adhesion of the membrane ( 3 ) to the foam body. The membrane ( 3 ) comprises a side lap ( 5 ) extending sidewardly of at least some of the marginal edges of the body ( 4 ). The inner liner ( 2 ) comprises joint formations for forming a nested side lap joint between adjacent panels. The joint formations comprise a first joint formation ( 20 ) at one edge of the liner ( 2 ) and a second joint formation ( 21 ) on an opposite edge of the panel. The first and second joint formations ( 20, 21 ) of adjacent panels are adapted to interengage on assembly and are clinched together using a clinching tool ( 22 ) to form a clinched joint ( 25 ). The first joint formation ( 20 ) comprises a liner extension which is shaped to define a recess. There is an inturned liner leg and a return leg which define the liner recess therebetween. The second liner formation ( 21 ) comprises a liner extension which is shaped to define a projection which is engagable in the recess defined by the first liner extension ( 20 ). The liner projection is defined by an inturned liner leg which has a return lip to reinforce the projection. On assembly of adjacent panels on site, the liner formations ( 20 ), ( 21 ) are inter-engaged ed and clinched together. A foam filler ( 30 ) is provided at the joint.

1 - 29 . (canceled) 
     
     
         30 . A roof panel for forming a low pitch or a flat roof, the roof panel comprising:
 an inner liner;   an outer weatherproof membrane;   a body of insulating material between the inner liner and the outer membrane;   wherein the inner liner comprises joint formations for forming a nested side lap joint between adjacent panels.   
     
     
         31 . The roof panel as claimed in  claim 30  wherein the joint formations are adapted for clinching. 
     
     
         32 . The panel as claimed in  claim 30  wherein the joint formations comprise a first joint formation on one edge of the liner and a second joint formation on an opposite edge of the liner, the first liner formation of one panel being adapted for interengaging and for clinching with a second liner form of an adjacent panel. 
     
     
         33 . The panel as claimed in  claim 32  wherein the first liner formation comprises a liner extension which is shaped to define a recess. 
     
     
         34 . The panel as claimed in  claim 33  wherein the liner comprises an inturned leg and a return leg which define the liner recess therebetween. 
     
     
         35 . The panel as claimed in  claim 32  wherein the second liner formation comprises a liner extension which is shaped to form a liner projection for locating in the liner recess of an adjacent panel. 
     
     
         36 . The panel as claimed in  claim 35  wherein the liner comprises an inturned leg which defines the liner projection. 
     
     
         37 . The panel as claimed in  claim 36  wherein the liner projection has a return lip to reinforce the projection. 
     
     
         38 . The panel as claimed in  claim 30  comprising a fastener for fastening the panel to a support such as a purlin. 
     
     
         39 . The panel as claimed in  claim 38  wherein the fastener is a self-coring fastener. 
     
     
         40 . The panel as claimed in  claim 30  comprising a filler for location in the nested side lap joint forming portions of the inner liner. 
     
     
         41 . The panel as claimed in  claim 40  wherein the filler is of insulation material. 
     
     
         42 . The panel as claimed in  claim 30  wherein the membrane comprises an integral side lap extending sidewardly of at least some of the marginal edges of the insulation, and the side lap being extendable over the joint between adjacent panels to form a sealed joint between adjacent panels on assembly. 
     
     
         43 . The panel as claimed in  claim 30  wherein the membrane comprises a unitary sheet of membrane or film. 
     
     
         44 . The panel as claimed in  claim 30  wherein the membrane is substantially planar. 
     
     
         45 . The panel as claimed in  claim 30  wherein the membrane is of substantially uniform structure and thickness. 
     
     
         46 . The panel as claimed in  claim 30  wherein the membrane is of a flexible plastics material. 
     
     
         47 . The panel as claimed in  claim 30  wherein the membrane is attached to the insulation body except at a fixing region at one or more of the marginal edges. 
     
     
         48 . The panel as claimed in  claim 47  wherein the side lap of the membrane is extended to cover the fixing region on assembly. 
     
     
         49 . The panel as claimed in  claim 42  wherein the side lap extends for bonding to an adjacent panel on assembly. 
     
     
         50 . The panel as claimed in  claim 49  wherein the side lap is bonded to an adjacent panel on assembly. 
     
     
         51 . The panel as claimed in  claim 30  wherein the body of insulation comprises an insulation foam. 
     
     
         52 . The panel as claimed in  claim 51  wherein the insulation foam is factory formed in situ between the inner liner and the outer layer. 
     
     
         53 . The panel as claimed in  claim 30  wherein the inner liner is of metal. 
     
     
         54 . The panel as claimed in  claim 30  wherein the liner is a profiled liner. 
     
     
         55 . The panel as claimed in  claim 54  wherein the liner comprises nestable partial profiles at the side marginal edges thereof. 
     
     
         56 . The panel as claimed in  claim 55  wherein the joint formations are provided at the edge of the partial profiles. 
     
     
         57 . The panel as claimed in  claim 56  wherein the partial profiles are free of insulating material prior to assembly.