Importance

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Abstract

A prefabricated panel system which can be erected to form a watertight surface such as the roof or walls of buildings is described. The panels are structurally sufficient to bridge between spaced support beams. Each panel includes a rectangular sheet metal support subpanel having corrugations extending between and bridging the support members. A surface panel assembly comprising a Hypalon membrane intimately bonded to a thin, flat metal sheet by an epoxy adhesive is mounted on the corrugated subpanel by a foamed insulating layer. The corrugated metal panel extends beyond the foam and the surface panel assembly to form a corrugated lip. Hypalon fastener halves are disposed along each edge of the Hypalon sheet on flexible flaps for extending over the joint between adjacent panels and mating with similar fastener halves along edges of adjacent panels to form a watertight mechanical interconnection between the Hypalon membrane on adjacent panels. The top sheet is connected to the corrugated panel along the edges of the panel which extend across the support members to apply a tension force from the opposite edges of the corrugated panel to the opposite edges of the top metal sheet while permitting free two-dimensional motion between the two metal sheets as a result of greater thermal activity of one sheet than the other. The edges of the lower metal sheet are rolled to provide additional strength and extend beyond the edges of the top metal sheet. A foam joint filler is positioned over one rolled edge, and a flexible foam sealing strip is placed along the top of the other rolled edge and across the corrugated lip to form a vapor barrier when the panels are installed. In the assembled system, a plurality of panels are placed in edge-to-edge relationship such that each panel bridges the support members. Self-tapping fasteners then penetrate the joint filler and overlapped rolled edges of adjacent panels to fasten the opposite edges of the panels to the support members. The fastener halves are engaged to provide a continuous waterproof membrane extending across the joint between adjacent panels. Finally the joints at the intersection of four corners, which has a special configuration resulting from the relationship between the ends of mating fastener halves, are sealed to complete the waterproof membrane.

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First Claim