A low noise roof deck system eliminates the thermal expansion noises associated with metal decking and includes structural features that permit installation of composite roofing shingles directly over the deck without venting. The system includes a composite panel base layer surmounted by a layer of
A low noise roof deck system eliminates the thermal expansion noises associated with metal decking and includes structural features that permit installation of composite roofing shingles directly over the deck without venting. The system includes a composite panel base layer surmounted by a layer of water resistant material, a layer of foam synthetic resin insulation and a layer of mineral board. A second layer of mineral board may be overlaid on the first mineral board layer. The system is easily installed over a system of conventional underlying supports to provide a strong, rigid deck for supporting a waterproof composite shingle roof membrane and forming a quiet weatherproof roof system. The composite base panel has a layer of synthetic resin foam insulation sandwiched between a base layer of wood fibers bonded with an inorganic cement and an upper layer of a resin bonded wood product.
대표청구항▼
Having described the preferred embodiments of the present invention, the following is claimed as new and desired to be secured by Letters Patent: 1. A low noise roof deck system for supporting a composite shingle roof and for installation without a metal deck on a roof support member and comprising
Having described the preferred embodiments of the present invention, the following is claimed as new and desired to be secured by Letters Patent: 1. A low noise roof deck system for supporting a composite shingle roof and for installation without a metal deck on a roof support member and comprising: a. a composite base panel, the base panel having a lower first layer including wood fibers bonded with a noncombustible mineral cement, a middle second layer bonded to said first layer and including an insulation material, and an upper third layer bonded to said second layer and including a resin bonded wood product having a nailable surface; b. said base panel being adapted to be secured to the roof support member; c. a mineral board panel secured to the nailable surface in overlying relation to said base panel; d. said composite base panel and said mineral board panel being configured to support a composite shingle roof without thermal expansion or contraction noise associated with a metal deck and without venting; and e. a layer of a substantially water resistant material disposed between said composite base panel and said mineral board panel. 2. The low noise roof deck system as set forth in claim 1, further including a plurality of fasteners for securing said composite base panel to the roof support member and for securing said mineral board panel in overlying relation to said base panel. 3. The low noise roof deck system as set forth in claim 1, wherein said noncombustible mineral cement includes a component selected from the group consisting of magnesium oxide, magnesium sulfate, magnesium oxysulfate, sodium silicate and calcium carbonate. 4. The low noise roof deck system as set forth in claim 1, wherein said base panel first layer is selected from the group consisting of oriented strand board and chipboard. 5. The low noise roof deck system as set forth in claim 1, wherein said insulation material includes a foam synthetic resin material. 6. The low noise roof deck system as set forth in claim 5, wherein said foam synthetic resin material includes expanded polystyrene. 7. The low noise roof deck system as set forth in claim 6, further including a second mineral board panel disposed in overlying relation to said mineral board panel. 8. The low noise roof deck system as set forth in claim 1, wherein said resin bonded wood product comprises oriented strand board. 9. The low noise roof deck system as set forth in claim 1, wherein said substantially water resistant material is selected from the group consisting of felt paper and rosin paper. 10. The low noise roof deck system as set forth in claim 1, further including a layer of a second insulation material disposed between said substantially water resistant material and said mineral board panel. 11. The low noise roof deck system as set forth in claim 1, further including a layer of composite shingles positioned in overlying relation to said mineral board layer and forming a waterproof roofing membrane without venting. 12. A low noise roof system for installation without a metal deck and comprising: a. a roof deck system having a first composite panel, the panel having: a lower first layer including wood fibers bonded with an inorganic cement, a middle second layer bonded to said first layer and including a foam synthetic resin insulation, and an upper third layer bonded to said second layer and including a resin bonded wood product having a nailable surface; a layer of a second foam synthetic resin insulation disposed in overlying relation to said first composite panel; and a mineral board panel secured to the nailable surface in overlying relation to said layer of second insulation material; said first composite panel and said mineral board being configured to support a composite shingle roof without a metal deck; b. a plurality of composite shingles secured in overlying relation to said mineral board panel and forming a roofing membrane without venting; and c. a layer of a substantially water resistant material disposed between said first composite panel and said mineral board. 13. The low noise roof system set forth in claim 12, wherein said inorganic cement includes a component selected from the group consisting of magnesium oxide, magnesium sulfate, magnesium oxysulfate, sodium silicate and calcium carbonate. 14. The low noise roof system set forth in claim 12, wherein said mineral board panel is a first mineral board panel, and including a second mineral board panel disposed in overlying relation to said first mineral board panel. 15. The low noise roof system as set forth in claim 14, further including a plurality of fasteners for securing said first composite panel to the roof support member and for securing said first and second mineral board panels and said second layer in overlying relation to said first composite panel. 16. In a method for installing a low noise roof deck without a metal deck on a roof support member, the improvement including the steps of: a. installing a composite base panel, the base panel having a lower first layer including wood fibers bonded with an inorganic cement, a middle second layer including a foam synthetic resin insulation material bonded to said first layer, and an upper third layer bonded to said second layer and including a resin bonded wood product, by securing said base panel to the roof support member using a plurality of fasteners; b. next installing a layer of a substantially water resistant material in overlying relation to said composite base panel; c. next installing a layer of a second foam synthetic resin insulation material in overlying relation to said layer of substantially water resistant material; d. next installing a mineral board panel in overlying relation to said layer of the second foam synthetic resin insulation material using a plurality of fasteners that extend downwardly into said composite base panel; and e. next installing a plurality of composite shingles secured in overlying relation to said mineral board panel and forming a roofing membrane without venting. 17. The method for installing a roof deck as set forth in claim 16, including the step of: a. installing a second mineral board panel disposed in overlying relation to said mineral board panel. 18. The method for installing a roof deck as set forth in claim 17, including the step of: a. installing said layer of composite shingles positioned in overlying relation to said second mineral board panel and forming a waterproof roofing membrane.
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