FIELD

This application relates generally to the field of insulated roofing systems, components thereof, and methods of installing. More particularly to a plurality of support members that are operatively coupled to each other to provide space between structures for components, such as insulation.

BACKGROUND OF THE INVENTION

Buildings that utilize metal decking are typically large area, open floor steel frame buildings. The buildings typically are pre-engineered and are provided as kits of components for use in a wide range of industries, including agricultural, aircraft hangers, garages, riding arenas, indoor sports fields, warehouses, as well as commercial and governmental buildings. Steel buildings may feature open floor space, referred to as bays, and are commonly but not always, built on poured concrete slabs. Building members may comprise columns, beams, rafters, purlins, joists, girts, bracing, or the like. Vertical columns may be operatively coupled to the concrete slabs and extend from the concrete. The vertical columns may be operatively coupled to and support elongated rafters or trusses. Long bay purlins or joists may be operatively coupled to the rafters or trusses in a transverse orientation to the rafters. A plurality of roof panels may be operatively coupled to the purlins or joists with clips, such as standing seam clips. Typically, the clips provide a gap between the purlin or joists and the roof panels. Frequently, the gap is filled with insulation components and/or other building components to reduce heat transfer through the roof panels. There is a need to provide improved roof systems.

SUMMARY OF THE INVENTION

The embodiments of the present disclosure meet the needs discussed above. This is achieved by providing support members for roof systems, which enable positioning of roof panels of a roof apart from building members (e.g., roof building members). The space created by the support members allow building components such as insulation, to be placed between the roof panels and the roof building members. In some embodiments, each of the support members may be comprised of a single channeled component having three main portions. A first portion being a base portion (e.g., otherwise described as a foot portion), used to attach the support member to the roof building members. The second portion being an offset portion, used to increase the displacement between the roof panels and roof building members. The third portion being an upper portion, which is used to support the roof panel attachment via roof clips, as well as connecting adjacent support members. In alternative embodiments, as will be described in further detail herein, the channel may be continuous (as shown) or may be discontinuous, and the support member may have more than one channel. The support members may be utilized in new buildings or to retrofit existing buildings.

The roof system described herein improves upon traditional roof systems by improving the thermal resistance of traditional roof system. As such, embodiments of the roof system described herein achieves compliance with updated energy codes by way of using the support members. The support members described herein provide a larger gap for insulating components (e.g., compressible insulation, spray insulation, insulating thermal blocks, or the like) or other like building components. Consequently, the roof system with the support members described herein achieve the required thermal resistance for compliance with the energy codes while providing better, the same, or similar structural support and costs for production, transportation, and installation.

Embodiments of the invention comprise a support member for a roof system. The support member comprises a base portion, an upper portion, and an offset portion operatively coupling the base portion and the upper portion. The base portion, the upper portion, or the offset portion comprises a channel.

In further accord with embodiments, the channel extends from the base portion through the offset portion and into the upper portion.

In other embodiments, the support member is a stamped part.

In yet other embodiments, the channel comprises a lower channel flange, two upper channel flanges, and two webs operatively coupling the lower channel flange to the two upper channel flanges.

In still other embodiments, the channel comprises a first upper channel flange and a second upper channel flange, a first web and a second web, and a lower channel flange. The first web operatively couples the lower channel flange and the first upper channel flange, and the second web operatively couples the lower channel flange to the second upper channel flange.

In other embodiments, the channel is within the base portion, and wherein the channel diverges within the base portion.

In further accord with embodiments, a base portion width of the base portion is greater than an upper portion width of the upper portion or an offset portion width of the offset portion.

In other embodiments, the offset portion is operatively coupled to the upper portion through an upper radiused bend.

In still other embodiments, the offset portion is operatively coupled to the base portion through a lower radiused bend.

In yet other embodiments, the support member comprises a proximal end and a distal end. The distal end of the support member is configured for operative coupling with a proximal end of a second support member adjacent the support member.

In other embodiments, the proximal end comprises a nested end. The nested end comprises a nested channel. The nested channel comprises a nested lower channel flange, a first nested upper channel flange and a second nested upper channel flange, and a first nested channel web and a second nested channel web. The first nested channel web operatively couples the nested lower channel flange and the first nested upper channel flange. The second nested channel web operatively couples the lower nested channel flange to the second nested upper channel flange. The nested lower channel flange has a lower nested flange width that is less than a lower channel flange width of the lower channel flange.

Embodiments of the invention comprise a roof system comprising a plurality of building members, and a plurality of support members operatively coupled to at least one of the plurality of building members. Each of the plurality of support members comprise a base portion, an upper portion, and an offset portion operatively coupling the base portion and the upper portion. The base portion, the upper portion, or the offset portion comprise a channel. A distal end of a first support member is operatively coupled to a proximal end of a second support member adjacent the first support member.

In further accord with other embodiments, the channel extends from the base portion through the offset portion and into the upper portion.

In other embodiments, the channel comprises a lower channel flange, two upper channel flanges, and two webs operatively coupling the lower channel flange to the two upper channel flanges.

In yet other embodiments, the channel comprises a first upper channel flange and a second upper channel flange, a first web and a second web, and a lower channel flange. The first web operatively couples the lower channel flange and the first upper channel flange. The second web operatively couples the lower channel flange to the second upper channel flange.

In still other embodiments, the channel is within the base portion, and the channel diverges within the base portion.

In other embodiments, the offset portion is operatively coupled to the upper portion through an upper radiused bend and the offset portion is operatively coupled to the base portion through a lower radiused bend.

In further accord with embodiments, operatively coupling of the distal end of the first support member to the proximal end of the second support member comprises operatively coupling at the upper portion of the first support member and the upper portion of the second support member.

In other embodiments, the proximal end comprises a nested end. The nested end comprises a nested channel. The nested channel comprises a nested lower channel flange, a first nested upper channel flange and a second nested upper channel flange, and a first nested channel web and a second nested channel web. The first nested channel web operatively couples the nested lower channel flange and the first nested upper channel flange. The second nested channel web operatively couples the lower nested channel flange to the second nested upper channel flange. The nested lower channel flange has lower nested flange width that is less than a lower channel flange width of the lower channel flange. The nested channel at the proximal end of the second support member nests within the channel at the distal end of the first support member.

Embodiments of the invention comprise a method of installing a roof system. The method comprises assembling a plurality of support members to a building member. The plurality of support members comprises a base portion, an upper portion, and an offset portion operatively coupling the base portion and the upper portion. The base portion, the upper portion, or the offset portion comprises a channel. The proximal end of each of the plurality of support members is operatively coupled to a distal end of an adjacent support member of the plurality of support members. The method further comprises assembling first insulation between the plurality of support members and the building member and assembling second insulation above the plurality of support members. The method also comprises assembling a plurality of clips to the plurality of support members and assembling a plurality of panels to the plurality of clips.

The features, functions, and advantages that have been discussed may be achieved independently in various embodiments of the present invention or may be combined in yet other embodiments, further details of which can be seen with reference to the following description and drawings.

