System and method of forming at least a portion of a reinforced roof structure from sandwich panels

Abstract

A roofing system includes a first sandwich panel, a second sandwich panel and a support panel. The first sandwich panel, which forms at least a portion of the roof structure, has a first outer layer and a second outer layer spaced from the first outer layer by a panel core. The first sandwich panel includes a first angle edge, which includes an edge portion of the panel core and an edge portion of at least the first outer layer. The second sandwich panel includes a first outer layer and a second outer layer spaced from the first outer layer by a second panel core, wherein the edge portion of the first sandwich panel is supported, at least in part, by one or more outer surface Depending on the length of the roofing system and/or other design criteria, the roofing system includes one or more support panels secured between the first sandwich panel and the second sandwich panel to provide additional support for the roof structure.

1 . A roofing system comprising:
 a first sandwich panel having a first outer layer and a second outer layer spaced from the first outer layer by a panel core and a first angle edge comprised of an edge portion of the panel core and an edge portion of at least the first outer layer, wherein the first sandwich panel forms at least a portion of a roof structure;   a second sandwich panel having a first outer layer and a second outer layer spaced from the first outer layer by a second panel core, wherein the edge portion of the first sandwich panel is supported, at least in part, by one or more outer surface of the second sandwich panel;   one or more support panels secured between the first sandwich panel and the second sandwich panel to provide support for the roof structure.   
   
   
       2 . The roofing system of  claim 1 , wherein one or more support panels are positioned in a predetermined position between the first sandwich panel and the second sandwich panel. 
   
   
       3 . The roofing system of  claim 2 , wherein the one or more support panels are secured between the first sandwich panel and the second sandwich panel with a bonding material. 
   
   
       4 . The roofing system of  claim 3 , wherein the bonding material is an adhesive. 
   
   
       5 . The roofing system of  claim 3 , wherein a continuous layer of bonding material is applied between the one or more support panels and at least one of the first sandwich panel or the second sandwich panel. 
   
   
       6 . The roofing system of  claim 3 , wherein bonding material is applied in one or more non-contiguous regions between the one or more support panels and at least one the first sandwich panel or the second sandwich panel. 
   
   
       7 . The roofing system of  claim 1 , wherein the first sandwich panel is secured at an angle of 45 degrees or less as measured between the first sandwich panel and the second sandwich panel. 
   
   
       8 . The roofing system of  claim 1 , wherein the one or more support members are formed from at least two materials joined together. 
   
   
       9 . The roofing system of  claim 7 , wherein the one or more support members are spaced apart to form one or more channels between the first sandwich panel and the second sandwich panel. 
   
   
       10 . The roofing system of  claim 9 , wherein the one or more support members are spaced apart along an associated pitch of the roof structure. 
   
   
       11 . The roofing system of  claim 1 , further including a channel guide secured to at least a portion of the second sandwich panel, wherein the channel guide is configured to route moisture deposited on the roof structure in a predetermined manner. 
   
   
       12 . A method of manufacturing a roof structure with one or more support panels, the method comprising:
 providing a roofing panel that includes a first outer layer and a second outer layer spaced from the first outer layer by a panel core and a first angle edge comprised of an edge portion of the panel core and an edge portion of at least the first outer layer, wherein the roofing panel forms at least a portion of a roof structure;   supporting the roofing panel with a base sandwich panel having a first outer layer and a second outer layer spaced from the first outer layer by a second panel core, wherein the base sandwich panel is secured to an associated structure; and   securing one or more support panels between the roofing panel and the base panel to provide support for the roof structure.   
   
   
       13 . The method of  claim 12 , further including applying a continuous layer of bonding material between the one or more support panels and at least one of the roofing panel or the base panel. 
   
   
       14 . The method of,  claim 13 , further including applying bonding material in one or more non-contiguous regions between the one or more support panels and at least one of the roof panel or the base panel. 
   
   
       15 . The method of  claim 12 , further including positioning the one or more support panels in predetermined positions between the roofing panel and the base panel. 
   
   
       16 . The method of  claim 12 , further including securing the roofing panel at an angle of 45 degrees or less as measured between a first axis along a plane of the roofing panel and a second axis along a plane of the base panel. 
   
   
       17 . The method of  claim 12 , further including securing a channel guide to at least a portion of the base panel, wherein the channel guide is configured to route moisture deposited on the roof structure in a predetermined manner.