A high-strength and easily manufactured sandwich roof panel

Abstract

The invention relates to a roof panel (10) which can be positioned on a roof to provide protection against natural conditions in houses, factories, warehouses, shopping malls, and similar buildings, comprising at least one body (20) made of rock wool, at least one sheet plate (30) connected to the upper vicinity of the body (20), at least one base sheet (31) connected to the lower vicinity of the body (20), at least one connection extension (50) and at least one protrusion (40) positioned side by side on the sheet plate (30) along at least one first axis (I) and extending in a second axis (II) direction perpendicular to the first axis (I), characterized in that the protrusion (40) has a trapezoidal form (41), the connection extension (50) has a narrowing form (51) as it moves away from the sheet plate (30) and a rectangular prism form (52) at the upper part of the narrowing form (51) so as to allow technical elements such as a solar panel or a water tank to be connected onto it, that the connection extension (50) and the protrusion (40) comprise at least one filling cavity (60) on the sides facing the body (20), that the filling cavity (60) of the connection extension (50) contains polyisocyan urate (PIR) and / or polyurethane (PUR) material, and that the filling cavity (60) of the protrusion (40) contains polyisocyanurate (PIR), polyurethane (PUR), or rock wool material.

Description

[0001] A HIGH-STRENGTH AND EASILY MANUFACTURED SANDWICH ROOF PANEL

[0002] TECHNICAL FIELD

[0003] The invention relates to a roof panel, which can be positioned on a roof to provide protection against natural conditions in houses, factories, warehouses, shopping malls and similar buildings, comprising at least one body made of rock wool, at least one sheet plate connected to the upper vicinity of the mentioned body, at least one base sheet connected to the lower vicinity of the body, at least one connection extension positioned side by side on the mentioned sheet plate along at least one first axis and extending in a second axis direction perpendicular to the first axis, and at least one protrusion.

[0004] PRIOR ART

[0005] In the current technique, roof panels are designed in the form of a multi-layered structure in order to increase the energy efficiency of buildings and provide protection against external factors. While the outer surfaces are made of materials resistant to environmental conditions, the inner layer generally consists of a filling material that offers high insulation performance. These layers come together to provide both heat insulation and prevent moisture and water leakage inside the structure. In addition, lightness and ease of installation also play an important role in the design of roof panels. The main purpose of these panels is to ensure the longevity of buildings, minimize energy losses, and increase indoor comfort.

[0006] One of the roof panels preferred in the current technique is sandwich panels. Sandwich panels are designed to have a multi-layered structure in order to increase the durability and energy efficiency of buildings. Generally, there is an insulating filling material between two outer surfaces, namely the base and the top. This filling provides important functions such as heat, sound, and fire insulation. The outer surfaces of the panels are coated with metal, aluminum, or composite materials to provide resistance against external factors. The main purpose of sandwich panels is to enable buildings to offer a comfortable indoor environment with less energy consumption, while also accelerating construction processes with fast and practical installation. Although sandwich panels used in the current technique are successful in meeting the insulation needs of buildings, in some cases problems such as insufficient heat insulation and low ignition resistance are experienced. Especially in regions with high temperatures, these panels cannot sufficiently block heat, resulting in reduced energy efficiency and temperature imbalances indoors. At the same time, in areas where the risk of fire is high, low ignition resistance can lead to serious safety issues. In addition, during the installation of additional structures such as solar panels or water tanks on sandwich panels, problems such as the insufficiency of the load-bearing structure or the risk of deformation may arise. Such shortcomings reveal the necessity of improving the current sandwich panel systems.

[0007] As a result, all the problems mentioned above have made it necessary to bring an innovation in the relevant technical field.

[0008] BRIEF DESCRIPTION OF THE INVENTION

[0009] The present invention relates to a roof panel, intended to eliminate the disadvantages mentioned above and to bring new advantages to the relevant technical field.

[0010] An object of the invention is to provide a roof panel with increased strength to allow the connection of a solar panel thereon, and at the same time to be easily manufacturable.

[0011] In order to achieve all the objectives mentioned above and that will arise from the detailed description below, the present invention is a roof panel, which can be positioned on a roof to provide protection against natural conditions in houses, factories, warehouses, shopping malls and similar buildings, comprising at least one body made of rock wool, at least one sheet plate connected to the upper vicinity of the mentioned body, at least one base sheet connected to the lower vicinity of the body, at least one connection extension positioned side by side on the mentioned sheet plate along at least one first axis and extending in a second axis direction perpendicular to the first axis, and at least one protrusion. Accordingly, the novelty is that the mentioned protrusion has a trapezoidal form, the mentioned connection extension has a narrowing form as it moves away from the sheet plate in order to allow technical elements such as solar panels or water tanks to be connected onto it, and has a rectangular prism form at the upper part of the narrowing form, that the mentioned connection extension and the mentioned protrusion contain at least one filling cavity on the sides facing the body, that the filling cavity of the connection extension contains polyisocyanurate (PIR) and / or polyurethane (PUR) material, and that the filling cavity of the protrusion contains polyisocyanurate (PIR), polyurethane (PUR), or rock wool material. Thus, a roof panel with high strength is obtained.

[0012] A further embodiment of the invention is characterized in that at least one connection apparatus is provided between the mentioned connection extensions for connecting technical elements such as a solar panel or a water tank onto the mentioned connection extension. Thus, desired structures such as a solar panel or a water tank can be connected onto the roof panel.

[0013] A further embodiment of the invention is characterized in that the protrusion and the connection extension are positioned successively on the sheet plate. Thus, strenght can be provided against structures such as a solar panel or a water tank positioned on the roof panel.

[0014] A further embodiment of the invention is characterized in that the protrusions contain rock wool in their filling cavity, and the connection extensions contain PIR or PUR material in their filling cavity. Thus, the desired strength value can be achieved at the desired point in the roof panel.

[0015] A further embodiment of the invention is characterized in that both the protrusions and the connection extensions contain PIR material in their filling cavities. Thus, the roof panel can have different variations according to the need.

[0016] A further embodiment of the invention is characterized in that both the protrusions and the connection extensions contain PUR material in their filling cavities. Thus, a high-strength structure is obtained depending on the user’s preference.

[0017] A further embodiment of the invention is characterized in that the protrusions and the connection extensions contain both PIR and PUR materials together in their filling cavities. Thus, a versatile structure is obtained.

[0018] BRIEF DESCRIPTION OF THE FIGURE

[0019] In Figure 1 , a representative perspective view of the roof panel of the invention is given.

[0020] DETAILED DESCRIPTION OF THE INVENTION In this detailed description, the subject matter of the invention is explained with examples that are only intended to provide a better understanding of the subject and will not have any limiting effect.

[0021] In Figure 1 , a representative perspective view of at least one roof panel (10) of the invention is given. The mentioned roof panel (10) is essentially a sandwich panel. The roof panel (10) of the invention is used as a cladding material on the roofs, facades, or interior partitions of many structures such as construction site buildings, factories, and warehouses. With advantages such as fast production and installation capability, lightweight construction, and high insulation properties, it is widely used in architectural technology.

[0022] The roof panel (10) of the invention comprises at least one body (20). The mentioned body (20) is connected in such a way as to come into contact with the attic of the buildings. Essentially, the body (20) is the main chassis that allows the roof panel (10) to remain rigid and also provides heat and sound insulation. In the preferred embodiment of the invention, the body (20) is always made of rock wool material. Thanks to the body (20) made of rock wool, heat and sound insulation can be maintained at a maximum level in the roof part of the building. In addition to the advantages it provides in heat and sound insulation, the rock wool material is also non-combustible since it does not melt up to about 1000°C and does not contain organic components. In this way, it provides safety by preventing the spread of a possible fire. Therefore, the roof panel (10) can be preferred in industrial facilities, warehouses, and commercial buildings where the fire risk is high. The body (20) made of rock wool material, in addition to heat insulation and fire resistance, significantly reduces noise by absorbing sound waves thanks to its fibrous and porous structure. This feature can provide an advantage especially in industrial facilities, hotels, offices, and residential projects where sound insulation is important. The body (20) is essentially the wide and flat base of the roof panel (10), allowing the building roof to be covered. The body (20) may comprise a female and male joint detail to allow connection with other roof panels on it.

[0023] The roof panel (10) of the invention comprises at least one sheet plate (30) connected to the upper vicinity of the body (20). The mentioned sheet plate (30) is made of metal material and, by being positioned on the body (20), allows the formation of a hybrid structure. The roof panel (10) comprises at least one base sheet (31 ). The mentioned base sheet (31) is connected to the lower vicinity of the body (20). In a possible embodiment of the invention, the base sheet (31) can be made of aluminum, a different metal material, or a composite material. In a possible embodiment of the invention, at least one of the sheet plate (30) or the base sheet (31 ), or both, may have a perforated structure. In this way, by providing sound insulation in partitions and roofs, the soundproofing of the roof panel (10) can be increased.

[0024] On the sheet plate (30), there are at least one protrusion (40) and at least one connection extension (50) arranged successively along at least one first axis (I). The mentioned connection extension (50) is located on the sheet plate (30), and various technical elements are connected onto it by means of connection apparatuses. The mentioned protrusion (40), on the other hand, is positioned between two connection extensions (50) and allows the structure (such as a solar panel, water tank, etc.) to be placed on the roof panel (10) to remain rigidly in place. The protrusion (40) is integrally connected to the sheet plate (30) and serves as a rib, thereby increasing expansion resistance under hot and cold conditions and providing a strong roof panel (10) structure.

[0025] The protrusion (40) and the connection extension (50) located on the sheet plate (30) of the roof panel (10) of the invention are arranged successively. In a possible embodiment of the invention, there are two protrusions (40) and two connection extensions (50) on the sheet plate (30). In addition, extra protrusions may be present for interconnecting the roof panels. In a possible embodiment of the invention, while the protrusion (40) has at least one trapezoidal form (41), the connection extension (50) is defined by at least one narrowing form (51) in the shape of an inverted V at the base and at least one rectangular form (52) extending upward on the mentioned narrowing form (51). This structure narrows at the base and expands at the top, thereby forming the geometry of the connection extension (50).

[0026] Due to this special form of the connection extension (50), a connection can be made onto the rectangular form (52). In this way, a connection apparatus can be mounted onto the connection extension (50) without the need for any drilling process. While the connection extension (50) narrows at the base, it widens at the top. The angled structure on the side surfaces of the geometry allows the connection apparatus to be firmly seated. This connection extension (50), which offers a wide profile at the top and a narrow profile at the bottom, facilitates the placement of the apparatus and prevents slipping during installation. The connection apparatus is tightened and fixed with the help of a bolt without the need for drilling, and elements such as a solar panel or a water tank can be mounted onto it. Thanks to the geometric form of the connection extension (50), the mounting of the connection apparatus without drilling provides an advantage in terms of the water tightness of the roof panel (10). This creates a safer structure against rain and external weather conditions. Since drilling is not required, the integrity of the material is preserved and the strength of the connection points is not reduced.

[0027] In the roof panel (10) of the invention, at least one filling cavity (60) is located between the protrusion (40) and the connection extension (50) and the body (20). The mentioned filling cavity (60) is the region remaining between the body (20) and the connection extension (50), and between the body (20) and the protrusion (40), along at least one second axis (II). In the preferred embodiment of the invention, the filling cavity (60) contains at least one insulation filling made of polyisocyanurate (PIR) or at least one polyurethane (PUR). These insulation materials not only provide heat insulation but also provide durability especially against heavy and fixed structures such as solar panels or water tanks. Polyurethane (PUR) and polyisocyanurate (PIR) materials, thanks to their structures that do not undergo deformation even under high pressure, increase the load-bearing capacity of the roof panel (10) and balance the stress at the connection points. Thus, the weight of the structures to be mounted on the roof panel (10) does not negatively affect the performance of the roof panel (10), thereby providing a long-lasting and reliable structure.

[0028] In a possible embodiment of the invention, while the filling cavity (60) located between the protrusion (40) and the body (20) is filled with rock wool material, the filling cavity (60) located between the connection extension (50) and the body (20) can be filled with PUR or PIR material. In another possible embodiment of the invention, the filling cavity (60) located between the protrusion (40) and the body (20), and the filling cavity (60) located between the connection extension (50) and the body (20), can both be filled with PUR and PIR materials simultaneously.

[0029] In a possible embodiment of the invention, while the filling cavity (60) located between the protrusion (40) and the body (20) is filled with PIR material, the filling cavity (60) located between the connection extension (50) and the body (20) is filled with PUR material. In another possible embodiment of the invention, while the filling cavity (60) located between the protrusion (40) and the body (20) is filled with PUR material, the filling cavity (60) located between the connection extension (50) and the body (20) is filled with PIR material.

[0030] In a possible embodiment of the invention, while the filling cavity (60) located between the protrusion (40) and the body (20) is filled with PIR material, the filling cavity (60) located between the connection extension (50) and the body (20) is also filled with PIR material. In another possible embodiment of the invention, while the filling cavity (60) located between the protrusion (40) and the body (20) is filled with PUR material, the filling cavity (60) located between the connection extension (50) and the body (20) is also filled with PUR material. The fact that both PIR and PUR materials can optionally be used in the filling cavities (60) located between the connection extension (50) and the body (20), and between the protrusion (40) and the body (20), increases the flexibility and performance of the system. Depending on the need, using PIR material in one filling cavity (60) and PUR material in the other provides customized solutions for insulation and strength requirements in different regions. This flexibility allows the roof panel (10) to be more resistant against external factors and optimizes the load-bearing capacity of the structures to be mounted. In addition, the combined use of both PIR and PUR materials gives the roof panel (10) a versatile insulation and strength advantage, thereby increasing energy efficiency and structural integrity.

[0031] In the roof panel (10) of the invention, a surface forming process is applied to the sheet plate (30) in machines known in the art as roll forming machines. During the manufacturing process of the sheet plate (30), the sheet plate (30) is turned upside down and subjected to the surface forming process. At this stage, using molds prepared according to the desired geometric form of the protrusion (40) and the connection extension (50), filling cavities (60) are opened on the sheet plate (30). The molds ensure that the sheet plate (30) takes the desired form and that the filling cavities (60) are created with high precision. After the forming process is completed, PUR, PIR, or both materials together are optionally injected into the filling cavities (60) through a filling nozzle. The injection process ensures that the filling materials are tightly integrated with the sheet plate (30) in full compatibility. After the insulation material is completely filled, the sheet plate (30) is bonded to the body (20) by means of an adhesive. This bonding process creates a strong connection between the filling material and the sheet plate (30), thereby increasing the strength of the roof panel (10). At the same time, it optimizes properties such as heat and fire insulation. All of these processes are carried out with high-precision automation machines, ensuring fast and efficient production.

[0032] In line with all the explanations given above, the invention operates as follows; it has a body (20) on which the structures forming the roof panel (10) are positioned. The body (20) is made of rock wool material. A sheet plate (30) connected to the upper vicinity of the body (20) and a base sheet (31 ) connected to the lower vicinity of the body (20) are provided. On the sheet plate (30), a protrusion (40) and a connection extension (50) are positioned successively along the first axis (I). Between the mentioned protrusion (40) and connection extension (50) and the body (20), there is a filling cavity (60) extending along the second axis (II). This filling cavity (60) is completely filled with rock wool, polyisocyanurate (PIR), or polyurethane (PUR) materials. Therefore, a roof panel (10) is obtained that has increased fire resistance and mechanical impact resistance, as well as lightweight and easy installation features.

[0033] The scope of protection of the invention is defined in the claims attached hereto and cannot in any way be limited to what has been described in this detailed description for illustrative purposes. Indeed, it is clear that a person skilled in the art may, in light of the above explanations and without departing from the main concept of the invention, develop similar embodiments.

[0034] BRIEF DESCRIPTION OF THE REFERENCES

[0035] 10 Roof Panel

[0036] 20 Body

[0037] 30 Sheet Plate

[0038] 31 Base Sheet

[0039] 40 Protrusion

[0040] 41 Trapezoidal Form

[0041] 50 Connection Extension

[0042] 51 Narrowing Form

[0043] 52 Rectangular Form

[0044] 60 Filling Cavity

[0045] (I) First Axis

[0046] (II) Second Axis

Claims

CLAIMS1. A roof panel (10) which can be positioned on a roof to provide protection against natural conditions in houses, factories, warehouses, shopping malls, and similar buildings, comprising at least one body (20) made of rock wool, at least one sheet plate (30) connected to the upper vicinity of the body (20), at least one base sheet (31 ) connected to the lower vicinity of the body (20), at least one connection extension (50) and at least one protrusion (40) positioned side by side on the sheet plate (30) along at least one first axis (I) and extending in a second axis (II) direction perpendicular to the first axis (I), characterized in that the protrusion (40) has a trapezoidal form (41), the connection extension (50) has a narrowing form (51) as it moves away from the sheet plate (30) and a rectangular form (52) at the upper part of the narrowing form (51) so as to allow technical elements such as a solar panel or a water tank to be connected to the rectangular form (52) or to the sheet plate (30) without drilling, that the connection extension (50) and the protrusion (40) comprise at least one filling cavity (60) on the sides facing the body (20), that the filling cavity (60) of the connection extension (50) contains polyisocyanurate (PIR) and / or polyurethane (PUR) material, and that the filling cavity (60) of the protrusion (40) contains polyisocyanurate (PIR), polyurethane (PUR), or rock wool material.

2. A roof panel (10) according to claim 1 , characterized in that the filling cavity (60) of the protrusions (40) contains rock wool, and the filling cavity (60) of the connection extensions (50) contains PIR or PUR material.

3. A roof panel (10) according to claim 1 , characterized in that both the filling cavity (60) of the protrusions (40) and the filling cavity (60) of the connection extensions (50) contain PIR material.

4. A roof panel (10) according to claim 1 , characterized in that both the filling cavity (60) of the protrusions (40) and the filling cavity (60) of the connection extensions (50) contain PUR material.

5. A roof panel (10) according to claim 1 , characterized in that the filling cavity (60) of the protrusions (40) and the filling cavity (60) of the connection extensions (50) contain PIR and PUR materials together.

6. A roof panel (10) according to claim 1 , characterized in that the filling cavity (60) of the protrusions (40) contains PIR material, and the filling cavity (60) of the connection extensions (50) contains PUR material.

7. A roof panel (10) according to claim 1 , characterized in that the filling cavity (60) of the protrusions (40) contains PUR material, and the filling cavity (60) of the connection extensions (50) contains PIR material.

8. A roof panel (10) according to claim 1 , characterized in that at least one of the sheet plate (30) and the base sheet (31 ), or both, have a perforated form.

9. A roof panel (10) according to claim 1 , characterized in that at least one connection apparatus is provided between the connection extensions (50) for connecting technical elements such as a solar panel or a water tank onto the connection extension (50).

10. A roof panel (10) according to claim 1 or 9, characterized in that the mentioned connection apparatus is connected to the connection extension (50) by means of a tight fit.

11. A roof panel (10) according to claim 1 , characterized in that the protrusion (40) and the connection extension (50) are positioned successively on the sheet plate (30).

12. A roof panel (10) according to claim 1 , characterized in that it comprises 2 protrusions (40) and 2 connection extensions (50).

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