Flute filler

Abstract

A flute filler for a standing seam metal roof having a plurality of ribs and having valleys therebetween comprising is provided. The flute filler comprises a sheet having a plurality of planks secured thereto. The planks are arranged to be side by side at spaced intervals such that each plank is adapted to be disposed in a valley and the sheet overlies the planks when the flute filler is situated on the roof. A cover board and a roofing membrane may be disposed over the sheet of the flute filler. In order to situate the flute filler on the roof, the planks are placed in a valley of the standing seam roof which can be accomplished by unrolling a rolled flute filler.

What is claimed is: 
     
         1 . A flute filler comprising:
 a plurality of planks; and   a sheet   wherein the planks are secured to a sheet.   
     
     
         2 . A flute filler as set forth in  claim 1  wherein the plurality of planks are arranged side by side and spaced from one another. 
     
     
         3 . A flute filler as set forth in  claim 2  wherein the spacing between adjacent planks is at a regular interval. 
     
     
         4 . A flute filler as set forth in  claim 2  wherein the planks comprise an insulating material. 
     
     
         5 . A flute filler as set forth in  claim 4  wherein the planks comprise polystyrene or isocyanate insulating material. 
     
     
         6 . A flute filler as set forth in  claim 2  wherein the planks are secured to the sheet by an adhesive. 
     
     
         7 . A flute filler as set forth in  claim 2  wherein the planks are secured to the sheet with double sided tape. 
     
     
         8 . A flute filler as set forth in  claim 2  wherein the sheet is rectangular and has two end edges and two side edges. 
     
     
         9 . A flute filler as set forth in  claim 2  wherein each plank has a pair of end edges and a pair of sided edges. 
     
     
         10 . A flute filler as set forth in  claim 9  wherein each plank is secured to the sheet such that one end edge of the plank is at one of the side edges of the sheet and the plank extends toward the other of the side edges of the sheet such that the sheet overhangs the other of the end edges of the planks. 
     
     
         11 . A flute filler as set forth in  claim 10  wherein at least one plank is positioned such that one side edge of the plank is at one of the end edges of the sheet and another plank is positioned such that one side edge of the plank is spaced from the other of the end edges of the barrier layer such that the sheet overhangs the side edge of the other of the planks. 
     
     
         12 . A flute filler as set forth in  claim 2  wherein the plank is configured to be positioned between adjacent standing seams of a standing seam roof. 
     
     
         13 . A flute filler as set forth in  claim 2  wherein each plank has a rectangular cross section. 
     
     
         14 . A flute filler as set forth in  claim 2  wherein the flute filler can be rolled. 
     
     
         15 . A flute filler as set forth in  claim 2  wherein each plank has a trapezoidal cross section. 
     
     
         16 . A flute filler for a standing seam metal roof having a plurality of ribs and having valleys therebetween comprising:
 a sheet having a plurality of planks secured thereto, the planks arranged to be side by side at spaced intervals such that each plank is disposed in a valley and the sheets overlies the planks; and   a roofing membrane disposed over the sheet of the flute filler.   
     
     
         17 . A flute filler as set forth in  claim 16  further comprising a cover board disposed between the sheet and the roofing membrane. 
     
     
         18 . A flute filler as set forth in  claim 17  comprising a plurality of flute fillers and wherein the sheet of each flute filler is rectangular and has two end edges and two side edges. 
     
     
         19 . A flute filler system as set forth in  claim 18  wherein each plank has a pair of end edges and a pair of sided edges. 
     
     
         20 . A flute filler as set forth in  claim 19  wherein each plank is positioned such that one end edge of the plank is at one of the side edges of the sheet and the plank extends toward the other of the side edges of the sheet such that the sheet overhangs the other of the end edges of the planks. 
     
     
         21 . A flute filler as set forth in  claim 16  wherein the spacing between adjacent planks is uniform. 
     
     
         22 . A flute filler as set forth in  claim 16  wherein each plank comprises an insulating material. 
     
     
         23 . A flute filler as set forth in  claim 16  wherein each plank is positioned such that one end edge of the plank is at one of the side edges of the sheet and the plank extends toward the other of the side edges of the sheet such that the sheet overhangs the other of the end edges of the planks. 
     
     
         24 . A flute filler as set forth in  claim 16  wherein at least one plank is positioned such that one side edge of the plank is at one of the end edges of the sheet and another plank is positioned such that one side edge of the plank is spaced from the other of the end edges of the barrier layer such that the sheet overhangs the side edge of the other of the planks. 
     
     
         25 . A method of filling flutes in a standing seam roof having ribs and valleys comprising the steps of:
 providing a flute filler comprising a sheet and a plurality of planks secured on the sheet;   placing the plurality of planks in the valleys of the standing seam roof wherein the sheet is disposed over the planks and the standing seam roof while the planks are placed in the flutes.   
     
     
         26 . A method as set forth in  claim 25  further wherein the flute filler is rolled as provided and then unrolled so as to place the plurality of planks in the valleys of the standing seam roof between adjacent ribs.