Prefabricated module for a pitched roof element and pitched roof element for a building roof

Abstract

The present disclosure relates to a prefabricated module for a pitched roof element comprising a frame made of at least two first beams being arranged in a distance and running parallel to each other and two second beams running rectangular to the first beams and being connected to the ends of the first beams forming a compartment into which a first layer of an insulation is inserted and a pitched roof element for a building roof made of at least two modules, each comprising a frame made of at least first beams being arranged in a distance and running parallel to each other and two second beams running rectangular to the first beams and being connected to the ends of the first beams forming a compartment into which a first layer of an insulation is inserted.

Claims

1. A prefabricated module for a pitched roof element comprising a frame made of at least two first beams being arranged in a distance to each other and running parallel to each other and two second beams running perpendicular to the first beams and being connected to ends of the first beams forming a compartment into which a first layer of an insulation made of mineral fibers and a binding agent is inserted and comprising a second layer of the insulation being arranged above the first layer of the insulation, covering the frame and being fixed at least to the first and/or the second beams, whereby the second layer of the insulation has a higher bulk density than the first layer of the insulation and whereby the first beams have a length being at least equal to an extension of a roof between a ridge purlin and an inferior purlin, wherein the second layer of the insulation is a dual density board made of mineral fibers and a binding agent, the dual density board having two layers of different bulk densities, wherein the layer with the lower bulk density is oriented to the first layer of the insulation and to upper narrow surfaces of the first and the second beams.

2. The prefabricated module according to claim 1, wherein, the first beams and/or the second beams are connected to a cladding board being arranged adjacent to the first layer of the insulation and wherein a membrane is arranged adjacent to the second layer of the insulation.

3. The prefabricated module according to claim 1, wherein, the second layer of the insulation has a bulk density of at least 80 kg/m.sup.3 and/or a declared thermal conductivity of at least 0.038 W/(m.sup.2*K).

4. The prefabricated module according to claim 1, wherein, a membrane is arranged adjacent to the second layer of the insulation.

5. The prefabricated module according to claim 1, wherein, counter battens running parallel to the first beams and are fixed to the second beams whereby the second layer is arranged between the counter battens and the frame.

6. The prefabricated module according to claim 5, wherein, tiling battens are fixed to the counter battens whereby the tiling battens are running parallel to the second beams, the ridge purlin and the inferior purlin.

7. The prefabricated module according to claim 1, wherein, at least a further beam is disposed between outer first beams of the frame, whereby at least two compartments are provided between the outer first beams and whereby the compartments have identical dimensions in lengths and/or widths and/or depths.

8. The prefabricated module according to claim 1, wherein, the second layer of insulation has a thickness between 60 mm and 160 mm being thinner than the thickness of the frame and/or the first layer of insulation having a thickness of at least 200 mm.

9. The prefabricated module according to claim 1, wherein, the module has a thermal resistance Rc-value of 7.0 (m2*K)/W or higher.

10. A pitched roof element made of at least two modules according to claim 1, whereby the modules are connected pivotably to each other via a hinge being connected to a second beam of each frame so that the frames can be moved from a position in which the first beams of the frames are running parallel to each other and lying on each other to a position in which the frames enclose an angle between the first beams in the area of the hinge being at least equal to an angle between two halves of the roof element forming a V-shaped adjustment.

11. The pitched roof element according to claim 10, wherein, each module comprises a second layer of the insulation being arranged above the first layer of the insulation, covering the frame and being fixed at least to the first and/or the second beams, whereby the second layer of the insulation has a higher bulk density than the first layer of the insulation and whereby the first beams have a length being at least equal to an extension of the roof between a ridge purlin and an inferior purlin.

12. The pitched roof element according to claim 10, wherein, both modules are provided with at least one fixing point to which an element to keep the modules in the V-shaped adjustment are fixable at least until the modules are fixed to a building.

Description

DRAWINGS

(1) The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

(2) In the following the disclosure is described in more details with reference to the accompanying drawings, in which:

(3) FIG. 1 shows part of a building roof with pitched roof elements made of prefabricated modules in a perspective view;

(4) FIG. 2 shows a module in a perspective sectional view;

(5) FIG. 3 shows the module according to FIG. 2 with additional counter battens in a sectional side view;

(6) FIG. 4 shows the module according to FIG. 3 in an enhanced sectional side view and

(7) FIG. 5 shows a pitched roof element according to FIG. 1 in an enlarged sectional view of the connection of two modules.

(8) Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

(9) Example embodiments will now be described more fully with reference to the accompanying drawings.

(10) FIG. 1 shows a part of a building roof with three pitched roof elements 1 being arranged on a building assembly 2, such like in a family house. Each roof element consists of two modules 3, being described afterwards and being arranged in a V-shaped adjustment; each module 3 constitutes one half of the roof element 1.

(11) The modules 3 are connected via a hinge 4 being arranged in the area of a ridge purlin 5. Said hinge 4 allows the two modules 3 to be moved from a position in which the modules 3 are lying parallel to each other to a position shown in FIG. 1 in which the modules 3 enclose an angle between the modules 3 in the area of the hinge 4 and the ridge purlin 5 being equal to an angle between the two modules 3 of the roof element 1 forming the V-shaped adjustment on the building assembly 2.

(12) From FIG. 1 it can be seen that each half of the roof is constructed by using three modules 3 of which two outer modules 3 have an equal width and a module 3 being arranged between the outer modules 3 having a smaller width compared to the outer ones. The module 3 being arranged between the outer modules 3 has a width which approximately equals half of the width of the outer modules 3. The modules 3 are connected via screws which are not shown and which connect the modules 3 being neighbored to each other.

(13) It can be seen that the modules 3 span at least from the ridge purlin 5 to both inferior purlins 6.

(14) FIG. 1 furthermore shows an element 7 which keeps the modules 3 in the V-shaped adjustment and which is fixed to fixing points 8 and both modules 3 of the roof element 1. This element 7 can be fixed to the fixing points 8 before lifting the roof element 1 in the V-shaped adjustment to the building assembly 2 and can be removed after the roof element 1 is fixed to the building assembly 2.

(15) It is evident that it is of advantage to use two of these elements 7 on both sides of the roof element 1, especially if the roof element 1 is lifted in total on top of the building assembly 2. In connection with smaller modules 3 one element 7 may be sufficient and especially in case of a roof according to FIG. 1 consisting of three modules 3 on each half of the roof it is of advantage only to use one element 7 as this element 7 has to be removed before the next part of the roof, namely two modules 3 being connected by a hinge 4 are lifted to the top of the building assembly 2 and being connected to the already installed modules 3 of the roof element 1. This is normally the case in the construction of row houses.

(16) FIGS. 2 to 4 show the modules 3 in more detail. FIG. 2 shows a module 3 comprising a frame 9 made of three first beams 10 being arranged in a distance and running parallel to each other. Two second beams 11 running rectangular to the first beams 10 are connected to the ends of the first beams 10 via screws or nails. Additionally, glue can be used as connection device. The second beams 11 run parallel to each other in a distance to each other which is equal to the extension of the roof element 1 from the ridge purlin 5 to one inferior purlin 6 and an overlap of the roof element 1 with respect to the building assembly 2.

(17) Two neighbored first beams 10 and the two second beams 11 being arranged on either side of the first beams 10 provide a compartment 12 of rectangular shape into which a first layer 13 of an insulation made of mineral wool, i.e. mineral fibres and a binding agent is inserted. The first layer 13 is clamp fitted into the compartment 12 which means that the first layer 13 has a width being a little bit larger than the distance between the parallel running first beams 10.

(18) The thickness of the first layer 13 of the insulation corresponds to the height of the first beams 10 but it might be possible to use a compressible first layer 13 being a little bit thicker than the height of the first beams 10 and therefore the compartment 12 so that a total filling of the compartment 12 with insulation material is ensured.

(19) The first beams 10 and the second beams 11 are connected to a board 14 closing the compartments 12 on one side of the frame 9. Beams 10, 11 and board 14 are made of wood.

(20) The connection of the beams 10, 11 and the board 14 can be arranged by screws and/or nails and additionally by using an adhesive.

(21) According to FIG. 2 the prefabricated module 3 is provided with a second layer 15 of the insulation being made of boards consisting of mineral wool, i.e. mineral fibres and a binding agent. The board is a dual density board having an average density of about 90 kg/m3 and a declared thermal conductivity of about D=0.038 W/(m*K). As this board is a dual density board it has two layers (not shown) of different bulk densities whereby the layer with the lower bulk density is oriented to the first layer 13 of the insulation which means to surfaces 16 of the beams 10, 11.

(22) It can be seen from FIG. 2 that the boards of the second layer 15 run from one outer first beam 10 to the second outer first beam 10 covering the first beam 10 being arranged in the middle between the two outer first beams 10. Furthermore, it can be seen that the lengthwise direction of the board constituting the second layer 15 is perpendicular to the lengthwise direction of the first layer 13 being made from a mineral fibre web.

(23) Finally, the module 3 according to FIG. 1 shows a vapor permeable membrane 17 covering the second layer 15 and being fixed by nails 18 running through the second layer 15 to the beams 10, 11. Often nail fixing of the vapor permeable membrane 17 will take place with and through the counter battens 19.

(24) The membrane 17 is waterproof and protects the module 3, especially the insulation material but also wooden beams against water ingress which can cause damages to the insulation and/or the mechanical parts of the module 3. It can be seen that part of the membrane covers the outside of the first beams 10 and of course the membrane 17 can be arranged in a way that also the outer parts of the second beams 11 are covered by the membrane 17.

(25) One main aspect of the module 3 shown in FIG. 2 is that because of the second layer 15 having a higher bulk density than the first layer 13 the module 3 is sufficient for walking on the module 3 even in areas of the insulation without causing damages to the insulation. This advantage is achieved in that a second layer 15 made of boards is used having a high bulk density of more than 80 kg/m3, especially more than 120 kg/m3, a certain thickness and a dual density characteristics so that this results in a high mechanical resistance indicated by a point load resistance of at least 120 kPa respectively 600 N per 50 cm.sup.2 at a deformation of 5 mm according to European Standard EN 12430. FIGS. 3 and 4 additionally show counter battens 19 running parallel to the first beams 11 and being fixed to the first beams 10 and in the area of the second beams 11 to the second beams 11 as well for example by using nails (not shown) running through the second layer 15 into the surfaces 16 of the beams 10, 11. On top of the counter battens 19 tiling battens 20 are arranged running parallel to the second beams 11, the ridge purlin 5 and the inferior purlin 6. These tiling battens 20 are arranged in a certain distance to each other which corresponds to devices being used for a roof covering. These devices may be tiles, especially plain tiles. With respect to the counter battens 19 it has to be pointed out that these counter battens 19 are arranged exactly over the first beams 10. The tiling battens 20 can be fixed to the counter battens 19 by nails running through the counter battens 19, the second layer 15 into the first beams 10.

(26) FIG. 3 shows a specific example of a module 3 with four compartments 12 divided by first beams 10 being arranged at a center distance of 610 mm to each other. Each beam 10 has a thickness of 30 mm and a height of 220 mm so that a first insulation layer 13 has a thickness of 220 mm, too which may be achieved after a small compression of the first layer 13.

(27) The second layer 15 consists of mineral wool boards, especially made of stone wool and binding agent having a thickness of 60 mm resulting in a total height of the module 3 without the counter battens 19, 20 of 290 mm being the addition of the height of the second layer 15, the first layer 13 and the thickness of the cladding board 14 being 10 mm. The second layer 15 being made of dual density boards eliminates thermal bridges and makes it possible to stand on the whole surface of the module 3. The module 3 according to the disclosure establishes a safe vapor-open construction which can be easily handled as a prefabricated module or a prefabricated roof element 1 which decreases the time needed to build up a roof on a building assembly 2. Mineral wool provides for a very low value of water vapor diffusion resistance which may be assumed to be equal to =1. The insulation layer will thus ensure that the moisture being included in the construction may easily disappear without causing any harm. A construction as has been described above and as is further shown in FIG. 4 with a construction height of 290 mm, a 10 mm cladding board 14 (chipboard, =10) in the bottom and a vapor permeable membrane 17 (e.g. MorgoVent 120, =200) on top, will result in an overall d-value for the total construction equal to d=0.4298 m. A simulation with the Glaser tool based on EN ISO 13788, climate class 2 confirms that no condensation and thus no accumulation of moist will appear in the construction. So, due to the vapor openness of the insulation and the membrane 17 the wooden beams are protected by an internal climate. The internal moisture percentage of the wood is protected and thereby a durable roof construction is ensured. This is yet another big benefit of a pitched roof construction utilizing modules and elements according to the present disclosure.

(28) Furthermore, the second layer 15 provides a higher additional value in terms of acoustics and of course thermal accumulation and fire safety. The thermal performance of a construction, here the roof element 1 and the modules 3 is indicated by its thermal resistance or the Rc-value according to e.g. Dutch Standard NEN 1068 and will be at a minimum of 7.0 W/(m2*K). Depending on the thickness of the second layer 15 the thermal resistance can be in the range between 60 mm for Rc=7.0 W/(m2*K) via 100 mm for Rc=8.0 W/(m2*K) to 140 mm for Rc=9.0 W/(m2*K) or even higher.

(29) FIG. 5 shows the pitched roof element 1 according to FIG. 1 in an enlarged side view of the connection of two modules 3 via the hinge 4. The hinge 4 consists of two wooden ledges 23 being connected pivotably to each other and each being fixed to one module 3 via screws 24. The ledges 23 run along the whole module 3.

(30) Furthermore, it can be seen from FIG. 5 that a strip 25 of insulation material is inserted between the two modules running from the ridge to the hinge 4. On top of the strip 25 a further ledge 27 is arranged in a profile element 28 clamped and fixed between the two modules 3 and being used to carry a ridge tile 22 covering a part of the uppermost tiles 21 being arranged on top of the roof element 1 and being connected to the tiling batten 20 with one end and being in contact with the second end on the outer surface of the tile 21 being arranged adjacent to. Finally, FIG. 5 shows a board 26 being connected to the wooden ledges 23 and thereby closing the gap between the two cladding boards 14 of the two modules 3 being connected to each other via the hinge 4.

(31) The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.