CA1197764A - Insulation board - Google Patents
Insulation boardInfo
- Publication number
- CA1197764A CA1197764A CA000435577A CA435577A CA1197764A CA 1197764 A CA1197764 A CA 1197764A CA 000435577 A CA000435577 A CA 000435577A CA 435577 A CA435577 A CA 435577A CA 1197764 A CA1197764 A CA 1197764A
- Authority
- CA
- Canada
- Prior art keywords
- insulation board
- facing sheet
- fibers
- scrim
- strands
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Landscapes
- Laminated Bodies (AREA)
- Paper (AREA)
- Building Environments (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
An insulation board comprising a plastic foam layer which is covered by at least one facer, the facer comprising (a) a sheet of glass fibers, the fibers being bonded to each other by a bonding agent, the fibers and bonding agent being coated with a non-wicking agent, whereby, although the fibrous facing sheet is porous to permit venting of gases and vapors, it is substantially liquid-repellant to prevent bleed through by various types of liquids, and (b) a scrim between the facing sheet and the plastic foam layer, the scrim comprising a sheet, prefereably made of glass fibers similar to the facing sheet, and having a pattern of glass strands over one face thereof.
An insulation board comprising a plastic foam layer which is covered by at least one facer, the facer comprising (a) a sheet of glass fibers, the fibers being bonded to each other by a bonding agent, the fibers and bonding agent being coated with a non-wicking agent, whereby, although the fibrous facing sheet is porous to permit venting of gases and vapors, it is substantially liquid-repellant to prevent bleed through by various types of liquids, and (b) a scrim between the facing sheet and the plastic foam layer, the scrim comprising a sheet, prefereably made of glass fibers similar to the facing sheet, and having a pattern of glass strands over one face thereof.
Description
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*
SPECIFICATION
~ his invention relates -to insulation panels or boards, and it particularly relates to insulation boards that are most satis~actorily utili~ed ln roofing.
A roof construction generally comprises a roo~ deck which may be made of various materials such as wood, concrete, gypsum, steel, and the like, an insulation barrier above the deck and a roof covering which usually comprises at least one layer of asphalt topped by a felt layer that is topped by ano-ther layer Of asphalt. Generally about three such successive layers are usedO Sometimes a layer of gravel or the like is super-imposed on the top layer of asphalt.
~ he insula~ion barrier, itself, may comprise one or more layers of insulating sheets placed on top of each other at the building site or it may comprise a prefabricated laminated board. ~he laminated type of insulation board generally comprises a plastic foam layer or core, which may be polurethane, polyisocyanate, or the like, and has, at least on one side, a protective or facing layer that may be either rigid or flexible and is usually fire or flame retardant. When there are two such protective layers, one on each side of the foam layer, it is generally referred to as a "sandwich"
construction.
Plastic foams are used as core material in sandwich panels because of low heat transmission, rigidity light weight, moisture-proofness and chemical inertness.
1.
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Facers that are commonly used lnclude expanded perlite boards, metal foils, organic felt, plywood, hardboard, cement-asbestos board, reinforced plastic, tempered glass and glass fiber board. Since the foam core is isolated from small ignition sources by the facer, ignition resistance depends primarily upon the degree of protection afforded by the facer.
The bottom facers should, in addition, be capable of retarding ingress of fluids because this type of insula~ion board is usually made by placlng the bottom facers on a slatted conveyor belt and applying an even distribution of liquid foam material thereon~
The foam, thereafter, expands and solidifies during movement of -the conveyor. If the facers were to permit bleeding through of the liquid foam material, this material would stick and harden on the conveyor slatg, thereby ma~ing the conveyor inoperative until cleaned~
The necessity for such constant cleaning would seriously impair commercial production.
The ability to vent fluids such as vaporized liquids and gases is impor-tant in this ~type of insulation board. Such fluids may cause frothing or bubbling of the asphalt when the hot asphalc is applied to the facing.
Evaporation of li~uid fluids, or expansion of entrapped ` gases and vapors, may cause asphalt blistering. Therefore, there must be some means present ~or venting fluids such as vaporize~ liquids or gases.
In order to vent such fluids it has been the
*
SPECIFICATION
~ his invention relates -to insulation panels or boards, and it particularly relates to insulation boards that are most satis~actorily utili~ed ln roofing.
A roof construction generally comprises a roo~ deck which may be made of various materials such as wood, concrete, gypsum, steel, and the like, an insulation barrier above the deck and a roof covering which usually comprises at least one layer of asphalt topped by a felt layer that is topped by ano-ther layer Of asphalt. Generally about three such successive layers are usedO Sometimes a layer of gravel or the like is super-imposed on the top layer of asphalt.
~ he insula~ion barrier, itself, may comprise one or more layers of insulating sheets placed on top of each other at the building site or it may comprise a prefabricated laminated board. ~he laminated type of insulation board generally comprises a plastic foam layer or core, which may be polurethane, polyisocyanate, or the like, and has, at least on one side, a protective or facing layer that may be either rigid or flexible and is usually fire or flame retardant. When there are two such protective layers, one on each side of the foam layer, it is generally referred to as a "sandwich"
construction.
Plastic foams are used as core material in sandwich panels because of low heat transmission, rigidity light weight, moisture-proofness and chemical inertness.
1.
7~;~
Facers that are commonly used lnclude expanded perlite boards, metal foils, organic felt, plywood, hardboard, cement-asbestos board, reinforced plastic, tempered glass and glass fiber board. Since the foam core is isolated from small ignition sources by the facer, ignition resistance depends primarily upon the degree of protection afforded by the facer.
The bottom facers should, in addition, be capable of retarding ingress of fluids because this type of insula~ion board is usually made by placlng the bottom facers on a slatted conveyor belt and applying an even distribution of liquid foam material thereon~
The foam, thereafter, expands and solidifies during movement of -the conveyor. If the facers were to permit bleeding through of the liquid foam material, this material would stick and harden on the conveyor slatg, thereby ma~ing the conveyor inoperative until cleaned~
The necessity for such constant cleaning would seriously impair commercial production.
The ability to vent fluids such as vaporized liquids and gases is impor-tant in this ~type of insulation board. Such fluids may cause frothing or bubbling of the asphalt when the hot asphalc is applied to the facing.
Evaporation of li~uid fluids, or expansion of entrapped ` gases and vapors, may cause asphalt blistering. Therefore, there must be some means present ~or venting fluids such as vaporize~ liquids or gases.
In order to vent such fluids it has been the
2.
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usual practice to provide venting base sheets which may he perforated, grooved or ribbed felts that ~orm lateral escape channels for the fluids.
In accordance with the present invention, not only are the usual venting sheets eliminated and their function provided by the facing sheets themselves but the porosity o~ the facing sheets are considerably reduced (although still retaining sufficient porosity to permit lateral venting of any vapors formed between the foam layer and the roof covering) and the dimensional stability, flexural strength, fastener pull-through strength, board spanability, impact-resistance, wind-uplift performance and surface traffic performance are considerabIy improved in a manner which will become better understood by reference to the following description when read in conjunction with the accompanying drawings wherein:
Figure l, is a sectional view of an insulated roof construction including the insulation board of the present invention~
Figure 2, is a perspective view of an insulation board embodying the present invention.
Figure 3, is a perspective view of a scrim used in the present inventionO
Referring now in greater detail to the figures of the drawing wherein similar reference characters refer to similar parts, there is shown a roof construction, generally designated 10, which includes a deck 12, here shown as being made of concrete, an asphalt layer l~ above
7~
usual practice to provide venting base sheets which may he perforated, grooved or ribbed felts that ~orm lateral escape channels for the fluids.
In accordance with the present invention, not only are the usual venting sheets eliminated and their function provided by the facing sheets themselves but the porosity o~ the facing sheets are considerably reduced (although still retaining sufficient porosity to permit lateral venting of any vapors formed between the foam layer and the roof covering) and the dimensional stability, flexural strength, fastener pull-through strength, board spanability, impact-resistance, wind-uplift performance and surface traffic performance are considerabIy improved in a manner which will become better understood by reference to the following description when read in conjunction with the accompanying drawings wherein:
Figure l, is a sectional view of an insulated roof construction including the insulation board of the present invention~
Figure 2, is a perspective view of an insulation board embodying the present invention.
Figure 3, is a perspective view of a scrim used in the present inventionO
Referring now in greater detail to the figures of the drawing wherein similar reference characters refer to similar parts, there is shown a roof construction, generally designated 10, which includes a deck 12, here shown as being made of concrete, an asphalt layer l~ above
3.
the deck, latera~ly butted insulation boards, generally designated 16, which are joined at 18, and a roof covering 20. Although not specifically shown, this roof covering is preferably, but not necessarily, a so-called BUR type formed by successive layers of asphalt and roofing felt, usually three to four layers of each.
~ he insulation boards 16, which are the subject of the present invention, comprise a foam core 22, here shown as being made of pol~urethane or polyisoc~ana-te foam, a facer sheet 24 at the top of the foam core and a facer sheet 26 at the bottom of the foam core.
Both of the facer sheets 24 and 26 are of the same construction, and each comprises very fine glass fibers bonded together with polyvinyl acetate; about 90%
of the facer being glass.
Attached to each facer sheet is a scrim, as at 28 and 30. Both scrims are of the same size and construction and scrim 30, shown in Fig. 3, is illustrative of both.
~ he scrim shown in Fig. 3 comprises a glass mat or sheet 32, of the same general construction as the facers 24 and 26, but applied to one face of -the mat 32 is a grid formed by glass threads or s-trands 34. In the scrim of Fig. 3, the glass threads are of about 4 pounds tensile strength and are arranged in a pattern of ahout 1.8 ~-trands per inch in both directions. ~he strands are coated and are bound at each contact point with the same type of binder that is used in the production
the deck, latera~ly butted insulation boards, generally designated 16, which are joined at 18, and a roof covering 20. Although not specifically shown, this roof covering is preferably, but not necessarily, a so-called BUR type formed by successive layers of asphalt and roofing felt, usually three to four layers of each.
~ he insulation boards 16, which are the subject of the present invention, comprise a foam core 22, here shown as being made of pol~urethane or polyisoc~ana-te foam, a facer sheet 24 at the top of the foam core and a facer sheet 26 at the bottom of the foam core.
Both of the facer sheets 24 and 26 are of the same construction, and each comprises very fine glass fibers bonded together with polyvinyl acetate; about 90%
of the facer being glass.
Attached to each facer sheet is a scrim, as at 28 and 30. Both scrims are of the same size and construction and scrim 30, shown in Fig. 3, is illustrative of both.
~ he scrim shown in Fig. 3 comprises a glass mat or sheet 32, of the same general construction as the facers 24 and 26, but applied to one face of -the mat 32 is a grid formed by glass threads or s-trands 34. In the scrim of Fig. 3, the glass threads are of about 4 pounds tensile strength and are arranged in a pattern of ahout 1.8 ~-trands per inch in both directions. ~he strands are coated and are bound at each contact point with the same type of binder that is used in the production
4.
~3~
of the mat, which, in this instance, comprises polyvinyl acetate (PVA). The strength of the scrim can be varied by varying the strand diameter and grid pattern, bu-t the pattern shown in Fig. 3 is the most preferable.
The scrims 28 and 30 are generally applied to the respective facer sheets 24 and 26 after the facer sheets have been formed, but while still wet; this reactivates the PVA binder so that no additional binder is required.
The scrims and their method of construction do not form any part of the present invention except insofar as they are used in the combination forming the present insulation boards or panels.
The thickness of the facers may vary between about 4 to 120 mils, although the preferable range is between about 7 to 30 mils.
The glass fibers are treated with a non-wicking agent such as a fluorcarbon, silicone or silanes. The non-wicking agent is added after -the glass fiber product, including both the facer and the scrim, is formed, but while it is still in the wet state. The non-wicking agent coates both ~he glass f~bers and -~he polyvinyl acetate binder. This coating substantially prevents absorption into or adsorption onto the fibers of any liquids, whereby liquids that enter form beads on the , surfaces of the fibers.
In effect, the non-wicking agent is a liquid , repellent which permits the facers to shed no-t only water 7
~3~
of the mat, which, in this instance, comprises polyvinyl acetate (PVA). The strength of the scrim can be varied by varying the strand diameter and grid pattern, bu-t the pattern shown in Fig. 3 is the most preferable.
The scrims 28 and 30 are generally applied to the respective facer sheets 24 and 26 after the facer sheets have been formed, but while still wet; this reactivates the PVA binder so that no additional binder is required.
The scrims and their method of construction do not form any part of the present invention except insofar as they are used in the combination forming the present insulation boards or panels.
The thickness of the facers may vary between about 4 to 120 mils, although the preferable range is between about 7 to 30 mils.
The glass fibers are treated with a non-wicking agent such as a fluorcarbon, silicone or silanes. The non-wicking agent is added after -the glass fiber product, including both the facer and the scrim, is formed, but while it is still in the wet state. The non-wicking agent coates both ~he glass f~bers and -~he polyvinyl acetate binder. This coating substantially prevents absorption into or adsorption onto the fibers of any liquids, whereby liquids that enter form beads on the , surfaces of the fibers.
In effect, the non-wicking agent is a liquid , repellent which permits the facers to shed no-t only water 7
5.
.
~,. .
:`
`
~77~
but hot asphalt and any llquid foam ingredients.
However, there is sufficient absorbancv between the mating surfaces of the foam and facer on the one side and between the hot ~sphalt and facer on the other side to create a bond. ~he important thing is that the non-wicking agent prevents total ~leeding through of the liquids because the pressure of the liquids is less intense in the interior of the facing sheets than at the interfaces with the other materials.
lQ ~he above-described facer structure, including both the facing sheet and the scrim, al-thouyh capable of repelling liquids r thereby preventing impregna-tion and bleed-through by either hot asphalt or liquid foam ingredients, is nevertheless porous because of the fiber construction so that it will not trap any vapors. Since it is porous, it permits lateral venting of any vapors from between the foam layer and the roof covering.
Facers or panels of -the above-described construction, including the combination of facing sheet and scrim, are commercially available and, in themselves, do not constitute any part of the present invention ; except insofar as they are used in the present combination to form the facers for insulation boards of the present type.
Both the mat and strand portions of the scrims 28 and 30 have been described as made of ylass; however, they may be constructed of other materials such as nylon,
.
~,. .
:`
`
~77~
but hot asphalt and any llquid foam ingredients.
However, there is sufficient absorbancv between the mating surfaces of the foam and facer on the one side and between the hot ~sphalt and facer on the other side to create a bond. ~he important thing is that the non-wicking agent prevents total ~leeding through of the liquids because the pressure of the liquids is less intense in the interior of the facing sheets than at the interfaces with the other materials.
lQ ~he above-described facer structure, including both the facing sheet and the scrim, al-thouyh capable of repelling liquids r thereby preventing impregna-tion and bleed-through by either hot asphalt or liquid foam ingredients, is nevertheless porous because of the fiber construction so that it will not trap any vapors. Since it is porous, it permits lateral venting of any vapors from between the foam layer and the roof covering.
Facers or panels of -the above-described construction, including the combination of facing sheet and scrim, are commercially available and, in themselves, do not constitute any part of the present invention ; except insofar as they are used in the present combination to form the facers for insulation boards of the present type.
Both the mat and strand portions of the scrims 28 and 30 have been described as made of ylass; however, they may be constructed of other materials such as nylon,
6.
~. ~lb~ ~71~; ~
polyester, polyolefin, etc.. Nevertheless, the glass is preferable because of its inorganic nature, which makes it generally more flame-resistant than organic polymers.
This invention has been illustrated in th~ form of "sandwich" panels or boards wherein the foam layer is covered with a facer on both sides, but it may also embrace a board having a facer of this type only on one side. The other side may have another type of facer or none at all, depending on the manner in which it is to be used. Furthermore, although the invention has been described wi-th particular relation to roofing, it i5 also possible to utïlize these boards for other types of insulation.
~. ~lb~ ~71~; ~
polyester, polyolefin, etc.. Nevertheless, the glass is preferable because of its inorganic nature, which makes it generally more flame-resistant than organic polymers.
This invention has been illustrated in th~ form of "sandwich" panels or boards wherein the foam layer is covered with a facer on both sides, but it may also embrace a board having a facer of this type only on one side. The other side may have another type of facer or none at all, depending on the manner in which it is to be used. Furthermore, although the invention has been described wi-th particular relation to roofing, it i5 also possible to utïlize these boards for other types of insulation.
7.
Claims (12)
1. An insulation board comprising a plastic foam layer covered by at least one facing panel, said panel comprising a facing sheet, said facing sheet comprising glass fibers which are randomly dispersed in uniform fashion throughout the sheet, said fibers being bonded together by a bonding agent, and said fibers and bonding agent being coated by a non-wicking agent to provide a porous but liquid-repellent structure, said panel also including a scrim, said scrim being positioned between the facing sheet and the foam layer, the scrim comprising a glass fiber mat wherein the fibers are randomly dispersed and bonded together by a bonding agent, and wherein a pattern of glass strands are bonded to at least one face of the mat.
2. The insulation board of claim 1 wherein the strands are arranged in the form of a grid pattern.
3. The insulation board of claim 1 wherein the strands are arranged in the form of a grid pattern having crossed strands wherein the strands are bonded together at their intersections.
4. The insulation board of claim 1 wherein the strands are of about 4 pounds tensile strength and are arranged in a grid pattern of about 1.8 strands per inch in both directions of the grid.
5. The insulation board of claim 1 wherein the scrim is bonded to the facing sheet.
6. The insulation board of claim 1 wherein the scrim is bonded to the facing sheet by the same 8.
bonding agent that bonds the fibers of the facing sheet together.
bonding agent that bonds the fibers of the facing sheet together.
7. The insulation board of claim 1 wherein the glass fibers constitute about 90 percent by volume of the facing sheet.
8. The insulation board of claim 1 wherein the facing sheet has a thickness of between about 4 to 120 mils.
9. The insulation board of claim 1 wherein the facing sheet has a thickness of between about 7 to 30 mils.
10. The insulation board of claim 1 wherein the glass fibers in the facing sheet have diameters of between about 3.75 to about 13.0 microns and lengths of between about 0.25 to about 1.0 inch.
11. The insulation board of claim 1 wherein a facing sheet is bonded to each side of said Plastic foam.
12. The insulation board of claim 1 wherever the fibers and bonding agent of the scrim are also coated by a non wicking agent.
9.
9.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US06/474,153 US4414265A (en) | 1982-06-21 | 1983-03-10 | Insulation board |
| US474,153 | 1983-03-10 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1197764A true CA1197764A (en) | 1985-12-10 |
Family
ID=23882384
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000435577A Expired CA1197764A (en) | 1983-03-10 | 1983-08-29 | Insulation board |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1197764A (en) |
-
1983
- 1983-08-29 CA CA000435577A patent/CA1197764A/en not_active Expired
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEC | Expiry (correction) | ||
| MKEX | Expiry |