New patent application published for: SYSTEMS AND METHODS OF RETROFITTING A METAL ROOF

SYSTEMS AND METHODS OF RETROFITTING A METAL ROOF

Claims

1. A roofing system for installation of a new metal roof on an existing metal roof formed of metal panels, the existing metal roof comprising panel projections, the roofing system comprising: a first bracket and a second bracket, each of the first and second brackets comprising: a first flange comprising a first aperture to receive a fastener to secure the first flange to the existing metal roof; a mid-wall extending from the first flange, the first flange extending from a first side of the mid-wall; and a second flange with a second aperture for a fastener, the second flange extending from a second side of the mid-wall; a first rigid panel of insulation comprising a bottom wall, a top wall, and a slot formed through the bottom wall and extending toward the top wall, the slot comprising a geometry configured to receive a panel projection of the existing metal roof; a first clip attachable to the second flange of the first bracket, the first clip comprising a first tab; a second clip attachable to the second flange of the second bracket, the second clip comprising a second tab; a first metal panel positionable over the first rigid panel, comprising: a first edge comprising a first portion of a first panel projection and a hem configured to be engaged by the first tab of the first clip; and a second edge comprising a second portion of a second panel projection and a catch configured to extend over the second tab of the second clip.
2. The roofing system of claim 1, further comprising a spacer with a length of at least 24 inches, wherein in use, the spacer extends from the first clip, over the first rigid panel, and to the second clip to prevent unintended or inadvertent movement of the tabs of the first and second clips.
3. The roofing system of claim 1, wherein the first rigid panel comprises a first sidewall oriented approximately parallel to the slot, wherein the first sidewall has a first height, and wherein the mid-wall of the first bracket has a second height equal to or greater than the first height.
4. The roofing system of claim 1, wherein the first clip comprises a base with a base aperture to receive a fastener extendable through the second aperture of the second flange of the first bracket to couple the first clip to the first bracket, and wherein the first tab comprises a first end and a second end, the first end movably secured to the base, and the second end comprises a hook configured to engage the hem of the first metal panel.
5. A rigid panel of insulation configured to be positioned on an existing metal roof which includes a panel projection, comprising: a first sidewall, a second sidewall, a first endwall, and a second endwall, wherein: the first sidewall is spaced from the second sidewall to define a width of the rigid panel; and the first endwall is spaced from the second endwall to define a length of the rigid panel, the length being greater than the width; a bottom wall; a top wall spaced from the bottom wall to defining a thickness of the rigid panel; and a slot formed through the bottom wall and extending toward the top wall, the slot extending from the first endwall to the second endwall, wherein the slot has a geometry configured to receive the panel projection.
6. The rigid panel of claim 5, wherein the width is between approximately 23 inches and approximately 25 inches.
7. The rigid panel of claim 5, wherein a vertical reference plane extending parallel to the first sidewall bisects the rigid panel, and wherein a central reference plane that bisects the slot is offset from the vertical reference plane by a predetermined distance.
8. The rigid panel of claim 7, wherein the predetermined distance is between approximately 0.1 inch and approximately 1 inch.
9. The rigid panel of claim 5, wherein the slot comprises a first slot sidewall and a second slot sidewall.
10. The rigid panel of claim 9, wherein at least a portion of the first slot sidewall is oriented at an oblique angle to the first sidewall.
11. The rigid panel of claim 10, wherein at least a portion of the first slot sidewall is oriented approximately parallel to the first sidewall.
12. The rigid panel of claim 9, wherein at least a portion of the first slot sidewall is oriented approximately parallel to the first sidewall.
13. The rigid panel of claim 5, wherein the slot has a shape that is one of the following: generally rectangular in a cross-section; and generally trapezoidal in a cross-section.
14. The rigid panel of claim 5, wherein the thickness of the rigid panel is between approximately 4 inches and approximately 12 inches.
15. The rigid panel of claim 5, further comprising a rabbet recessed into the top wall and the first sidewall, the rabbet extending from the first endwall to the second endwall along the first sidewall.
16. The rigid panel of claim 15, further comprising a tongue extending away from the bottom wall, the tongue extending from the first endwall to the second endwall along the first sidewall.
17. The rigid panel of claim 16, wherein the rabbet has a depth and the tongue has a height, the height being approximately equal to the depth.
18. The rigid panel of claim 15, wherein the top wall is planar between an inner edge of the rabbet and a second inner edge of a second rabbet recessed into the top wall and extending along the second sidewall.
19. The rigid panel of claim 5, wherein the rigid panel comprises a foam insulation.
20. A method of installing a new metal roof on an existing metal roof which comprises panel projections, the method comprising: affixing a first bracket to the existing metal roof on a first side of a panel projection such that an upper flange of the first bracket extends toward the panel projection; affixing a first clip to the upper flange; affixing a second bracket to the existing metal roof on a second side of the panel projection such that an upper flange of the second bracket extends away from the panel projection; affixing a second clip to the upper flange of the second bracket; positioning a first rigid panel of insulation between the first bracket and the second bracket with the panel projection received in a slot formed in the first rigid panel; positioning a first metal panel over the first rigid panel such that: a first edge of the first metal panel is engaged by a hook of the first clip; and a second edge of the first metal panel is positioned over a hook of the second clip.