CA1223424A - Phenolic roof insulation - Google Patents

Phenolic roof insulation

Info

Publication number
CA1223424A
CA1223424A CA000449383A CA449383A CA1223424A CA 1223424 A CA1223424 A CA 1223424A CA 000449383 A CA000449383 A CA 000449383A CA 449383 A CA449383 A CA 449383A CA 1223424 A CA1223424 A CA 1223424A
Authority
CA
Canada
Prior art keywords
panel
heat insulating
slot
insulating panel
core
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
Application number
CA000449383A
Other languages
French (fr)
Inventor
Eric Stern
Sunil Vidyarthi
Norris Light
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Imperial Oil Ltd
Original Assignee
Imperial Oil Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Imperial Oil Ltd filed Critical Imperial Oil Ltd
Priority to CA000449383A priority Critical patent/CA1223424A/en
Application granted granted Critical
Publication of CA1223424A publication Critical patent/CA1223424A/en
Expired legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B29/007—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B29/005—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to another layer of paper or cardboard layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/08—Corrugated paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/78—Heat insulating elements
    • E04B1/80—Heat insulating elements slab-shaped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/24—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
    • E04C2/246—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 combinations of materials fully covered by E04C2/16 and E04C2/20
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0285—Condensation resins of aldehydes, e.g. with phenols, ureas, melamines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/30—Fillers, e.g. particles, powders, beads, flakes, spheres, chips
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Acoustics & Sound (AREA)
  • Electromagnetism (AREA)
  • Laminated Bodies (AREA)
  • Building Environments (AREA)

Abstract

PHENOLIC ROOF INSULATION
ABSTRACT OF THE DISCLOSURE

A flat rigid heat insulating panel for building structures comprising first and second oppositely disposed surfaces; a core comprised of rigid foam material between the first and second surfaces; a slot extending through the first surface and through the core; and a flexible foam filler within the slot.

Description

This invention relates to heat insulating panels which include a core of foam material for use in construction of heat insulated building structures, such as built up roofs. More particularly it relates to an improved heat insulating panel which, when included in a built up roof, will curl only a negli~ible amount so providing a more satisfactory finished roof than previously obtainable.
BACKGROUND OF THE INVENTION
The use of foamed plastic material for insulating purposes in building structures such as exterior or partitioned walls, bulk heads, ceilings, floors, storage tanks, and roof structures ls well known, as such foamed plastic materials have a very low thermal conductivity. Such foamed plastic materials having low thermal conductivity may, for instance, comprise phenolic foam material such as, for example, thermo set phenol formaldehyde materials. Other low thermal conductivity foamed materials may comprise polystyrene foam, urethane foam, and/or isocyanurate foam.
The foamed materials which are used as roofing insulation have a density of about 1.5 to about 6 pounds per foot3 so as to have sufficien~
strength to support persons and their equipment.
Typically, the foamed material is sandwiched between a pair of protective skins, such as for example paper or paper composites. The protective skins serve as a convenient means for making the heat insulating panels and also protect and maintain the integrity of the foamed material.
One problem experienced with respect to such known heat insulating panels, such as roofing panels, is associated with the curling or warping of the panels. Various structures have been suggested to alleviate this problem such as the cutting of slots across the panel and taping along the slot surfaces in an attempt to alleviate the stress in the panel. Such stress is caused by the imbalance in the stress induced by the process of manufacture of the panel and also by outside influences such as the heat of the sun, when utilizing produced panels. The slitting and taping of panels to prevent curling is disclosed in Canadian patent application 364,571 filed on November 13, 1980, and although this prior disclosed solution does prevent curling, the slit formed in the panel reduces the insulation qualities of the panel in the area of the slit and therefore reduces the efficiency of the panel in the aspect for which it was produced.

i2~34'Z~

It is also known to cover an insulation panel of this type with an aluminum skin which again reduces curling to a certain degree, mainly when the panels are exposed to the sun during installation. However the curling caused by the imbalances of stress induced during the process of manufacturing the panel still occurs with a panel covered with an aluminum skin, after it is covered with a roofing membrane and exposed to high outside temperatures There is therefore a need for an insulation panel having a foam core which exhibits only negligible curling during and after installation and heat losses through slits are ~inimized.
SUMMARY OF THE INVENTION
The insulating panel of this invention consists of a foamed plastic material core which has slots cut completely or partially through it and has a flexible filler such as polyurethane foamed within the slots to hold the panel together, assure flexibility of the sections of panel with each other and produce handling integrity of the panel so that it can be treated as a solid panel during handling and installation.
Preferably, the slots are also cut at right angles in the panel to achieve better flexibility of the panel.
The panel of this invention thus does not have any breaks in the insulative quality due to the slots as they are filled with a filler, and it exhibits high resistance to curling when exposed to conditions of temperature differences that induce visible curling in unslit panels.
Preferred embodiments of the invention wi71 now be described with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a perspective view of a panel of this invention;
Figure 2 is a cross-sectional view taken on line II-II of Figure l;
Figure 2a is a cross-sectional view showing an alternative embodiment to that shown in Figure 2, and Figure 3 is a cross-sectional view taken on line III-III of Figure 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the figures there is shown a panel 1 having a rigid foam insulation core 3 preferably of phenolic foam, corrugated paper board layers 5 on both sides of the core, and outer liners 7, again preferably of paper, adhered to the crests of the corrugated layer with a suitable adhesive, such
- 2 -~Z,23 ~2~

as, for example, a wet strength adhesive. Slots 9 and 11, of rectangular cross-section, are cut through the core 3, layers 5, and liners 7, and a foam filler 13 is injected within the slots 9 and 11 to completely fill them and secure together the sections of the panel which are separated by the slots.
The foam filler which is preferably a urethane foam filler, is flexible relative to the remainder of the panel and therefore slight curling can occur within parts of the panel without bending the whole panel.
~ y making a panel as shown in the figures, it will thus be noted that the panel has no apertures therethrough which are devoid of insulative material, as occurs in the prior art panels, and curling of panel sections occurs separately and without affecting the curling of the total panel, and hence a more satisfactory and efficient product ensues.
If a stronger panel is required, it is possible to leave the bottom skin intact and only cut the top skin of the panel to allow the introduction of flexible foam between the panel segments, as shown in Figure 2a.
The panel of this invention can be adhered to a roof substrate and a good bond can be assured as curling of the panel away from the substrate does not occur. As no, or very little curling occurs with the panel of this invention, the finished roof will also be relatively flat. It has been determined that the amount of curling which may occur in a two foot by four foot panel will only be approximately one eighth of an inch across the panel.
Although Figure 1 shows the use of slots both transversely and longitudinally through the panel, it is within the scope of this invention envisaged that the slots can merely be transversely situated through the panel or can be formed in any other suitable design for ease of manufacture or for other purposes. The only requirement is that the panel be separated into various parts which are each secured to one another by the flexible urethane foam filler so reducing curling across the major dimensions of the panel.
While preferred embodiments of the invention have been shown and described it will be understood that such are merely illustrative and that changes may be made to them without departing from the scope of the invention as claimed.

_ ~ _

Claims (6)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE PROPERTY OR
PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A flat rigid heat insulating panel for building structures comprising first and second oppositely disposed surfaces;
a core comprised of rigid foam material between said first and second surfaces;
a slot extending through the first surface and through the core; and a flexible foam filler within the slot.
2. The heat insulating panel of claim 1 wherein the slot also extends through the second surface.
3. The heat insulating panel of claim 1, wherein the slot is transversely across the panel.
4. The heat insulating panel of claim 1 or 2, wherein the slot is disposed longitudinally along the panel.
5. The heat insulating panel of claim 1, wherein the core is phenolic foam.
6. The heat insulating panel of claim 1, wherein the flexible filler is urethane foam.
CA000449383A 1984-03-12 1984-03-12 Phenolic roof insulation Expired CA1223424A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA000449383A CA1223424A (en) 1984-03-12 1984-03-12 Phenolic roof insulation

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA000449383A CA1223424A (en) 1984-03-12 1984-03-12 Phenolic roof insulation

Publications (1)

Publication Number Publication Date
CA1223424A true CA1223424A (en) 1987-06-30

Family

ID=4127379

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000449383A Expired CA1223424A (en) 1984-03-12 1984-03-12 Phenolic roof insulation

Country Status (1)

Country Link
CA (1) CA1223424A (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6258864B1 (en) 1999-01-20 2001-07-10 Cabot Corporation Polymer foam containing chemically modified carbonaceous filler
WO2003008724A1 (en) * 2001-07-17 2003-01-30 Saint-Gobain Isover A/S Flexible heat- and sound-insulating panel
US6586501B1 (en) 1999-01-20 2003-07-01 Cabot Corporation Aggregates having attached polymer groups and polymer foams

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6258864B1 (en) 1999-01-20 2001-07-10 Cabot Corporation Polymer foam containing chemically modified carbonaceous filler
US6586501B1 (en) 1999-01-20 2003-07-01 Cabot Corporation Aggregates having attached polymer groups and polymer foams
WO2003008724A1 (en) * 2001-07-17 2003-01-30 Saint-Gobain Isover A/S Flexible heat- and sound-insulating panel

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Legal Events

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