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 insulating panel to which roof tiles will be installed on a pitched roof, the roof insulating panel comprising:
 a panel of unitary construction 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 insulating panel and said second interlocking portion of said panel is adapted to mate with a first interlocking portion of a third roof insulating panel, and said overlap portion of said panel is adapted to overlap a third side of a fourth roof insulating panel, with said panel and the second, third and fourth roof insulating panels being of identical construction.   
   
   
       2 . The roof insulating 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, and said roof contacting portion defining a substantially planer, continuous lower surface.   
   
   
       3 . The roof insulating panel of  claim 2 , further comprising:
 said panel having a thickness which increases from said third side to said shoulder.   
   
   
       4 . The roof insulating panel of  claim 2 , wherein said upper surface between said first and second interlocking portions is substantially planer. 
   
   
       5 . The roof insulating 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 insulating 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 overlapping tile roof components thereto, the roof system comprising:
 a plurality of insulating panels of unitary construction, each said insulating panel adhered and bonded 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 mates with said second interlocking portion of a second said insulating panel and said second interlocking portion of said first insulating panel mates with said first interlocking portion of a third said insulating panel, and said overlap portion of said first insulating panel overlaps said third side of a fourth said insulating panel, with said first, second, third and fourth insulating panels being of identical construction;   a first polymer adhesive adhering said plurality of insulating panels to the pitched roof deck and adhering said overlap portion of said first insulating panel to said fourth insulating panel; and   a second polymer adhesive adhering the overlapping tile 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 adhered to the pitched roof deck. 
   
   
       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, and adhering the roof tiles to the insulating panels with an adhesive after adhering the insulating panels to the pitched roof deck.   
   
   
       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 by providing a panel tail surface against which the roof tiles abut.