IE20090126A1

IE20090126A1 - An insulated gutter

Info

Publication number: IE20090126A1
Application number: IE20090126A
Authority: IE
Inventors: Gregory Flynn; James Carolan
Original assignee: Kingspan Res & Dev Ltd
Priority date: 2008-02-28
Filing date: 2009-02-18
Publication date: 2009-09-16
Also published as: GB2457798A; GB2457798B; GB0902723D0

Abstract

A pre-fabricated composite gutter panel 30 comprises an outer dry side skin 5 which is of a PVC sheet, an inner wet side skin 6 and a core 7 of insulation material between the skins 5,6. The wet side skin 6 is of steel which is pre-coated with a waterproof plastisol paint. <Figure 3>

Description

The invention relates to an insulated gutter system, especially an insulated roof gutter system. The invention also relates to a composite gutter panel.

Various types of insulated roof gutter systems are known. There are however a number of problems with such conventional systems. Some systems are difficult and / or complex to manufacture, assemble, and / or fit on site. Other systems are not effectively and efficiently sealed leading to leakage problems and / or inferior insulation properties. Further systems are expensive in requiring special membranes.

This invention is directed towards providing an improved gutter system and especially a composite gutter panel which will overcome at least some of these difficulties.

Statements of Invention According to the invention there is provided a pre - fabricated composite gutter panel comprising:- an inner wet side skin; an outer dry side skin; . , . , . p ,. , «Μ Rio the skins being formed into a gutter profile; and ; ............ a core of insulation between the shaped inner and outer skins; wherein the inner wet side skin is formed from metal which is pre - coated with a waterproof coating.

In one embodiment the wet side skin is formed from a pre - coated metal coil.

Preferably the wet side skin is formed from a pre - coated steel coil. *£090 1 2 6 -2In a preferred embodiment the pre-coat comprises a paint. The coating paint may be about 200 microns thick. The paint is preferably a plastisol paint. he gutter panel may have overlapping means for overlapping, an assembly, with another composite gutter panel. The panel may have a lateral extension of the inner skin at one end for overlapping with the inner skin of an adjacent panel, on assembly. Alternatively or additionally the panel has a lateral extension of the outer skin at one end for overlapping with the insulation core of an adjacent panel, on assembly .

In one case the outer skin includes joggle joint forming means which inter engage on assembly to form a joggle joint. fhe invention also provides a gutter system comprising at least two composite gutter panels of the invention with a joint therebetween.

In one case adjacent panels are over - lapped at the joint therebetween.

In one embodiment the gutter system comprises sealing means for sealing the joint between adjacent panels. The sealing means may comprise a separate waterproof membrane seal for application only over the joint between adjacent panels, l he sealing means may also be a strip of metal or the like. fhe separate membrane seal may be heat sealable at the joint.

Brief Description of the Drawings The invention will be more clearly understood from the following description thereof, given by way of example only, with reference to the accompanying drawings, in which:Fig. 1 is a longitudinal cross sectional view of a composite roof panel according to the invention; B09O12® -3Fig. 2 is a longitudinal cross sectional view of a joint between adjacent panels of Fig. 1; Fig. 3 is a cross - sectional view on the line Ill - III in Fig. 1: Fig. 4 is a longitudinal cross sectional view of another composite panel; Fig. 5 is a cross sectional view of a joint between adjacent panels of f ig. 4; and 11) Fig. 6 is an exploded isometric view of a gutter system of the invention.

Detailed Description Referring to the drawings and initially to Figs. 1 and 3 thereof there is illustrated a composite panel 30 of an insulated roof guttering system. A joint between two adjacent panels 30A, 30B of the roof guttering system is illustrated in Fig. 2.

Each panel 30 comprises an outer dry side skin 5, an inner wet side skin 6 and a core 7 of insulation material between the skins 5, 6. The outer skin or liner 5 is typically of PVC sheet, approximately 0.5 mm thick. The inner wet side skin is pre - coated with a waterproof coating. In this case the wet side skin is formed from a pre - coated metal coil. The skin is generally of steel and is about 1 mm thick. The coil may be provided with any suitable waterproof coating such as a plastisol type coating. The coating in this case comprises a paint'layer, typically about 200 microns thick. The paint may be a plastisol which is applied wet and cured during the coil coating process on one side (which is ultimately the wet side). This avoids the expense of a loose laid PVC membrane or a PVC pre-laminated membrane The core 7 may be of any suitable insulation material such as an insulation board of polyurethane insulation, for example that sold under the trade name Kraftboard.

Adjacent panels 30A, 30B are inter - engaged at a joint therebetween to form a guttering system. In this case, the inner skin 6 projects laterally of the insulating core 7 -4to inter - engage by overlapping onto a portion 6B of the inner skin 6 of an adjacent panel 30B.

To form a panel according to the invention the pre - coated inner coil 6 is first cut to a desired flat skin length. The sheet is then formed / profiled into a required shape such as that illustrated in Fig. 3 with the pre-coated side outermost. i he inner side of the inner skin 6 is then sprayed with a composite adhesive. Similarly one side of a pre-cut section of Kraftboard insulation 7 is also sprayed with the composite adhesive. After curing, the profiled pre-coated inner skin 6 is bonded to the insulation 7. Similarly, a pre - formed outer skin 5 is bonded to the other side of the insulation 7 to form an insulated gutter panel 1 which is a fully composite bonded panel.

It will be appreciated that the resultant panel is a substantially rigid insulated gutter panel which is readily overlapped as illustrated. In some cases the joint may be further sealed with a separate short length strip 50 which may be of a membrane material such as a PVC which can be heat bonded or adhesively bonded to the exposed face of the adjacent wet side skins at the joint therebetween. Such an arrangement is illustrated in Pig. 6. The jointing I sealing strip may also be of metal. Fig. 6 illustrates typical boundary wall type gutter but the invention also applies to other types of gutter including a valley type gutter.

Referring to Figs. 4 and 5 there is illustrated another panel 30 which is similar to the panel 20 described above with reference to Figs. 1 to 3 and like parts are assigned the same reference numerals. In this case the outer skin 5 partially overlaps the insulating core 7. a portion 5B of the skin 5 projecting laterally from one side to engage in a recess 25 formed by another portion 5A of the outer skin. An improved overlapping sealing engagement results. -5410 9 012 6 A major advantage of the invention is that a conventional pre - coated coil can be used to form the wet side skin of the gutter panel. A separate membrane bonded along the length of the sheet is not required. This greatly simplifies the process both from a manufacture and a fitting viewpoint, leading to a less expensive system.

It will be appreciated that any suitable form of inter - engaging / overlapping joint may be used. For example, for enhanced sealing a joggle ~ type joint may be provided.

Ihe invention is not limited to the embodiments hereinbefore described which may be varied in detail.

Claims

1. Λ pre - fabricated composite gutter panel comprising:an inner wet side skin; an outer dry side skin; the skins being formed into a gutter profile; and a core of insulation between the shaped inner and outer skins; characterised in that the inner wet side skin is formed from metal which is pre - coated with a waterproof coating.

2. A gutter panel as claimed in claim 1 wherein the wet side skin is formed from a pre coated metal coil.

3. A gutter panel as claimed in claim 1 or 2 wherein the wet side skin is formed from a pre - coated steel coil.

4. A gutter panel as claimed in any of claims 1 to 3 wherein the pre-coat comprises a paint.

5. A gutter panel as claimed in claim 4 wherein the pre-coat has a thickness of about 200 microns.

6. A gutter panel as claimed in claim 4 or 5 wherein the paint is a plastisol paint.

7. A gutter panel as claimed in any of claims 1 to 5 having overlapping means for overlapping, an assembly, with another composite gutter panel. IE 0 9 0 1 2 · -Ί

8. A composite gutter panel as claimed in claim 7 having a lateral extension of the inner skin at one end for overlapping with the inner skin of an adjacent panel, on assembly.

9. A composite gutter panel as claimed in claim 7 or 8 having a lateral extension of the outer skin at one end for overlapping with the insulation core of an adjacent panel, on assembly.

10. A composite gutter panel as claimed in any of claims 1 to 9 wherein the outer skin includes joggle joint forming means which inter - engage on assembly to form a joggle joint.

11. A composite gutter panel substantially as hereinbefore described with reference to the accompanying drawings.

12. A gutter system comprising at least two composite gutter panels as claimed in any of claims 1 to 11 with a joint therebetween.

13. A gutter system as claimed in claim 12 wherein adjacent panels are over lapped at the joint therebetween.

14. A gutter system as claimed in claim 12 or 13 comprising sealing means for sealing the joint between adjacent panels.

15. A gutter system as claimed in claim 14 wherein the sealing means comprises a separate waterproof membrane seal for application only over the joint between adjacent panels.

16. A gutter system as claimed in claim 15 wherein the separate membrane seal is heat sealable at the joint. (E09012 -8

17. A gutter system substantially as hereinbefore described with reference to the accompanying drawings.