Insulated pitched roof system and method of installing same

Abstract

The present invention is an insulated pitched roof system for a sloped deck in which an insulating component is adhered to the sloped deck and the roof tiles are adhered to the insulating component with an adhesive, preferably a polymer adhesive. The insulating component includes a board or sheet material which is adhered to the roof deck. The insulating component is preferably adhered directly to the roof deck with a polymer adhesive. The insulating component preferably includes interlocking sides for forming a water tight connection between adjacently joined insulating components. Additionally, the insulating components include an end lap portion to form an overlapping portion between adjacent rows of insulating components. In a preferred embodiment, the overlapping portion is adhered together to form a unitary insulative and waterproof layer.

1 . A roof panel comprising: 
 a panel having first and second opposing sides and third and fourth opposing sides, said first side having a first interlocking portion and said second side having a second interlocking portion; and    said fourth side being formed in an overlap portion,    wherein said first interlocking portion of said panel is adapted to mate with a second interlocking portion of a second roof panel and said second interlocking portion of said panel is adapted to mate with a first interlocking portion of a third roof panel, and said overlap portion of said panel is adapted to overlap a third side of a fourth roof panel, with said panel and the second, third and fourth roof panels being of identical construction.    
   
   
       2 . The roof panel of  claim 1 , further comprising: 
 said panel having an upper surface and a lower surface, said lower surface having a roof contacting portion and an overlapping lower portion, said roof contacting portion and said overlapping lower portion being separated by a shoulder.    
   
   
       3 . The roof panel of  claim 2 , further comprising: 
 said panel having a thickness which increases from said third side to said shoulder.    
   
   
       4 . The roof panel of  claim 2 , wherein said upper surface between said first and second interlocking portions is substantially planer.  
   
   
       5 . The roof panel of  claim 2 , wherein said shoulder has a height which is substantially equal to said panel thickness at said third side.  
   
   
       6 . The roof panel of  claim 1 , wherein said panel is made from polystyrene, polyurethane or polyisocyanurate.  
   
   
       7 . An insulated pitched roof system for insulating a pitched roof deck and attaching roof components thereto, the roof system comprising: 
 a plurality of insulating panels to be adhered and bonded to the pitched roof deck or to a roof substrate attached to the pitched roof deck, each said insulating panel having first and second opposing sides and third and fourth opposing sides, said first side having a first interlocking portion and said second side having a second interlocking portion, and said fourth side being formed in an overlap portion,    wherein said first interlocking portion of a first said insulating panel is adapted to mate with said second interlocking portion of a second said insulating panel and said second interlocking portion of said first insulating panel is adapted to mate with said first interlocking portion of a third said insulating panel, and said overlap portion of said first insulating panel is adapted to overlap said third side of a fourth said insulating panel, with said first, second, third and fourth roof panels being of identical construction;    a first polymer adhesive to adhere said plurality of insulating panels to the pitched roof deck or the roof substrate; and    a second polymer adhesive to adhere the roof components to said plurality of insulating panels.    
   
   
       8 . The insulated pitched roof system of  claim 7 , wherein said first and second polymer adhesives are identical.  
   
   
       9 . The insulated pitched roof system of  claim 7 , wherein said first and second polymer adhesives are polyurethanes.  
   
   
       10 . The insulated pitched roof system of  claim 7 , wherein said second polymer adhesive is a foamable polymer adhesive.  
   
   
       11 . The insulated pitched roof system of  claim 10 , wherein said second polymer adhesive is a plural component, liquid polyurethane foam.  
   
   
       12 . The insulated pitched roof system of  claim 7 , wherein said first polymer adhesive is a single component polymer adhesive.  
   
   
       13 . The insulated pitched roof system of  claim 11 , wherein said first polymer adhesive is a plural component, liquid polyurethane foam.  
   
   
       14 . The insulated pitched roof system of  claim 13 , wherein said first and second polymer adhesives are identical.  
   
   
       15 . The insulated pitched roof system of  claim 7 , wherein each said insulating panel includes a substantially flat lower surface to be adhered to the pitched roof deck or to the roof substrate.  
   
   
       16 . A method of installing an insulated pitched roof system having a plurality of roof tiles and a pitched roof deck, the method comprising the steps of: 
 adhering, with an adhesive, a plurality of insulating panels to the pitched roof deck to form a lower row of insulating panels and an upper row of insulating panels;    interlocking adjacent insulating panels to one another in the lower row and in the upper row;    overlapping a portion of the lower row of insulating panels with a portion of the upper row of insulating panels adhering the roof tiles to the insulating panels.    
   
   
       17 . The method of  claim 16 , further comprising the step of adhering the upper row of insulating panels to the lower row of insulating panels.  
   
   
       18 . The method of  claim 17 , wherein the adhering is accomplished with a polymer adhesive.  
   
   
       19 . The method of  claim 16 , wherein the overlapping upper row portion aids in the proper placement of the roof tiles on the lower row of insulating components.