CA2465309A1 - Composite water-resistant panels - Google Patents

Composite water-resistant panels Download PDF

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Publication number
CA2465309A1
CA2465309A1 CA002465309A CA2465309A CA2465309A1 CA 2465309 A1 CA2465309 A1 CA 2465309A1 CA 002465309 A CA002465309 A CA 002465309A CA 2465309 A CA2465309 A CA 2465309A CA 2465309 A1 CA2465309 A1 CA 2465309A1
Authority
CA
Canada
Prior art keywords
metal
sheet
composite panel
panel
composite
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.)
Abandoned
Application number
CA002465309A
Other languages
French (fr)
Inventor
Christopher Ponting
Ian Lewis Burns
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.)
Corus UK Ltd
Original Assignee
Individual
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 Individual filed Critical Individual
Publication of CA2465309A1 publication Critical patent/CA2465309A1/en
Abandoned legal-status Critical Current

Links

Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D3/00Roof covering by making use of flat or curved slabs or stiff sheets
    • E04D3/36Connecting; Fastening
    • E04D3/3605Connecting; Fastening of roof covering supported directly by the roof structure
    • E04D3/3606Connecting; Fastening of roof covering supported directly by the roof structure the fastening means being screws or nails
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B7/00Roofs; Roof construction with regard to insulation
    • E04B7/20Roofs consisting of self-supporting slabs, e.g. able to be loaded
    • E04B7/22Roofs consisting of self-supporting slabs, e.g. able to be loaded the slabs having insulating properties, e.g. laminated with layers of insulating material
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/292Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and sheet metal
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D3/00Roof covering by making use of flat or curved slabs or stiff sheets
    • E04D3/35Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation
    • E04D3/351Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation at least one of the layers being composed of insulating material, e.g. fibre or foam material
    • E04D3/352Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation at least one of the layers being composed of insulating material, e.g. fibre or foam material at least one insulating layer being located between non-insulating layers, e.g. double skin slabs or sheets

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Mechanical Engineering (AREA)
  • Roof Covering Using Slabs Or Stiff Sheets (AREA)
  • Laminated Bodies (AREA)
  • Building Environments (AREA)

Abstract

A composite panel comprising: a metal decking (1), optionally pre-coated with a decorative finish on it's bottom surface a profiled metal top sheet (3) provided with a pre-laminated, waterproof, membranous layer on it's top surface, an insulating layer (2) sanwiched between the top surface of the metal decking (1) and the bottom surface of the metal top sheet (3) and means (5, 7) for connecting the panel to a frame work (4) and/or another composite panel to form a substantially water resistant building or structure.

Description

COMPOSITE WATER-RESISTANT PANELS
This invention relates to composite panels, including but not strictly limited to panels for use in the construction of a flat roof. In particular, the invention relates to a prefabricated panel which can be conveniently and easily be fitted to a building or other construction, and a method for manufacture of such a panel.
Conventionally, flat roofs are built on site. The usual methods for manufacture involve the construction of a metal frame work onto which decking is layed and fixed.
A layer of insulation is then applied and finally a waterproof layer must be added. The application of the water proof layer, in particular, can be a time consuming process.
Typically this layer may be bonded, eg with hot asphalt or cold bitumen, or loose laid and ballasted with pebbles or concrete slabs. Alternatively, they may be mechanically fixed to the substrate.
Clearly in poor weather environments it is undesirable and inconvenient to have to carry out this multi-step process on site. Accordingly, the present invention aims to provide an article which can be manufactured in the factory and conveniently and easily located with a building or structure on-site.
In accordance with a first aspect the present invention, there is provided a composite panel comprising;
a metal decking, optionally pre-coated with a decorative finish on it's bottom surface a profiled metal top sheet provided with a pre-laminated, waterproof, membranous layer on it's top surface, an insulating layer sandwiched between the top surface of the metal decking and the bottom surface of the metal top sheet and means for connecting the panel to a framework and/or another composite panel to form a substantially water resistant building or structure.
In accordance with a second aspect, the invention provides a method for the manufacture of a composite panel comprising:
A, simultaneously roll-forming a metal sheet and a waterproof, membranous layer to provide a sheet laminate comprising a metal layer having a layer of waterproof, membranous material on it's top surface, B. roll-forming a second metal sheet, optionally applying a decorative coating to the bottom surface of the second metal sheet;
C. arranging the first and second metal sheet with the top surface of said second sheet opposing the bottom surface of said first sheet; and D, providing therebetween, a volume of insulating material.
Optionally steps A and B may be carried out simultaneously. Step D may, optionally, be carried out by injecting a foaming polymeric insulating material between the arranged metal; sheets, and allowing the composite to cure. Alternatively, step D may involve spraying a chemical bonding agent to the top surface of said second sheet and the bottom surface of said first sheet and providing therebetween an insulating material.
Insulating materials for use in accordance with the method may include, but are not strictly limited to; particle boards, mineral wool and polymeric foams.
Optionally, to improve bonding between the insulating material and the two plates, the method my further include a step where pressure is applied to the composite. The pressure may be applied by means of, for example, a vacuum table, a platen press, a bag press or nip rolling while the bonding agent cures. Other means of improving or accelerating bonding of the plates to the insulating material will no doubt occur to the skilled addressee.
Suitable waterproof, membranous materials for use in accordance with the invention include vulcanised elastomeric materials which may be pre-cured, prior to applying the metal sheet and non-vulcanised elastomeric materials which are applied to the sheet in uncured form, being capable of curing while in service.
Some more specific examples of suitable waterproof membranous materials include; styrene butadiene modified bitumen, atactic polypropylene modified bitumen, polyaplphaolefin modified bitumen, ethylene propylenediene monomer, chlorosulphonated polyethylene, polyvinyl chloride, copolymer alloys, polyisobutylene, butadiene acrylonitrile alloys and nitrite butadiene polymers, ethylene interpolymer, polyepichlorohydrin, chlorinated polyethylene and neoprene(chloroprene).
Suitable methods for applying these materials to the metal sheet will vary with the material to be used and will no doubt occur to the skilled addressee.
The metal sheeting may be profiled to meet the specific applications for which the panel is designed, for example, the bottom sheet may be castellated for use in roofing applications, to allow air circulation and/or the passing through of utility pipes and wires.
The sides of either or both metal sheets may be suitably profiled to permit a convenient interlocking fit between sides of adjacent panels.
The panels have various applications, particularly where water impermeability is a desirable feature for a structure. By suitable adaption of the panels to suitable scales and shapes and/or the membranous sheet laminate, they may be used in the efficient assembly of, for example; flat roofing, flashings, gutters, portable buildings, flooring and walkways, ducting and air handling, water or silage tanks, oil rigs, swimming pools and pool ceilings, planters, lining of underground structures, overhead doors and secret fix roofing.
For the purposes of exemplification, some embodiments of the invention will now be further described with reference to the following Figures, in which;
Figure 1 shows a first embodiment of a composite panel of the invention for use in a flat roofing application;
Figure 2 shows a second embodiment of a composite panel of the invention for use in a flat roofing application;
Figure 3 shows a third embodiment of a composite panel of the invention for use in a flat roofing application;
As can be seen from Figure 1, a composite roof panel according to the invention comprises a profiled metal decking 1 on its lower surface, a volume of injected polymeric insulating foam 2 filling a space defined between the profiled metal decking 1 and a metal top sheet 3 on the upper surface of the composite, the top sheet 3 having thereon a pre-laminated waterproof membranous material. The panel may mechanically fixed to a metal framework 4 for a roof, by fasteners 5. A foam thermal break 6 is fitted between adjacent panels mounted on the framework 4. A flat bracing piece 8 covers the top of the fasteners 5 is made watertight by heat or solvent welding waterproof cover strips, 7, along the joins connecting the bracing piece to the top sheets 3 of adjacent panels.
Figure 2 shows a broadly similar arrangement to that of Figurel, in this embodiment, the insulating material 2 is provided in the form of a board of polymeric foam or mineral wood insulation. Also, the welded waterproof membrane cover strips, 7 are extended to cover the protruding tops of the fasteners 5.
Figure 3 shows a third, alternative embodiment of a roof panel according to the invention. In this panel, it can be seen the adjoining sides of two adjacent panels are suitably profiled to interlock, thereby reducing opportunity for leakage between j oins. As in Figure 2, a cover strip 7 is extended to cover the top of a protruding fastener 5. As in figure l, the insulation 2 is provided in the form of an injected polymeric foam.
Suitable means for applying waterproof membrane strips as referred to in this description will vary with the materials used, but some suitable methods include; seeming with adhesive or solvent welding, mechanical fastening and hot air welding. It is to be understood this list is not exhaustive and other suitable means will not doubt occur to the skilled addressee.

Claims (13)

5
1. A composite panel comprising;
a metal decking (1), optionally pre-coated with a decorative finish on it's bottom surface a profiled metal top sheet (3) provided with a pre-laminated, waterproof, membranous layer on it's top surface, an insulating layer (2) sandwiched between the top surface of the metal decking (1) and the bottom surface of the metal top sheet (3) and means (5, 7) for connecting the panel to a framework (4) and/or another composite panel to form a substantially water resistant building or structure.
2. A composite panel as claimed in claim 1 characterised in that the insulating layer comprises one or more of; particle board, mineral wool and polymeric foams.
3. A composite panel as claimed in claim 1 or claim 2 characterised in that the insulating layer is chemically bonded to the metal decking and/or the metal top sheet.
4. A composite panel as claimed in claim 2 characterised in that the insulating layer comprises polymeric foam injected into a space between the top surface of the metal decking and the bottom surface of the metal top sheet.
5. A composite panel as claimed in any preceding claim characterised in that the panel is configured for use in the construction of a flat roof.
6. A composite panel as claimed in any preceding claim characterised in that the panel is configured for use in the construction of guttering.
7. A composite panel as claimed in any preceding claim wherein the waterproof membranous material is selected from; styrene butadiene modified bitumen, atactic polypropylene modified bitumen, polyaplphaolefin modified bitumen, ethylene propylenediene monomer, chlorosulphonated polyethylene, polyvinyl chloride, copolymer alloys, polyisobutylene, butadiene acrylonitrile alloys and nitrite butadiene polymers, ethylene interpolymer, polyepichlorohydrin, chlorinated polyethylene or neoprene (chloroprene).
8. A method for the manufacture of a composite panel comprising:
A. simultaneously roll-forming a metal sheet and a waterproof, membranous layer to provide a sheet laminate comprising a metal layer having a layer of waterproof, membranous material on it's top surface, B. roll-forming a second metal sheet, optionally applying a decorative coating to the bottom surface of the second metal sheet;
C. arranging the first and second metal sheet with the top surface of said second sheet opposing the bottom surface of said first sheet; and D. providing therebetween, a volume of insulating material.
9. A method as claimed in claim 8 characterised in that steps A and B are carried out simultaneously.
10. A method as claimed in claim 8 or claim 9 characterised in that step D
involves injecting a foaming polymeric insulating material between the arranged metal sheets and allowing the composite to cure.
11. A method as claimed in claim 8 or claim 9 characterised in that step D
involves spraying a chemical bonding agent to the top surface of said decking and the bottom surface of said top sheet and providing therebetween an insulating material.
12. A method as claimed in any of claims 8 to 11 characterised by the further step of applying pressure to the composite as it cures.
13. A method as claimed in claim 12 wherein the step of applying pressure involves the use of a vacuum table, a platen press, a bag press or a nip rolling apparatus.
CA002465309A 2001-11-07 2001-11-07 Composite water-resistant panels Abandoned CA2465309A1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/GB2001/004941 WO2003046306A1 (en) 2001-11-07 2001-11-07 Composite water-resistant panels

Publications (1)

Publication Number Publication Date
CA2465309A1 true CA2465309A1 (en) 2003-06-05

Family

ID=9909697

Family Applications (1)

Application Number Title Priority Date Filing Date
CA002465309A Abandoned CA2465309A1 (en) 2001-11-07 2001-11-07 Composite water-resistant panels

Country Status (5)

Country Link
US (1) US20050011155A1 (en)
EP (1) EP1442181A1 (en)
AU (1) AU2002212526A1 (en)
CA (1) CA2465309A1 (en)
WO (1) WO2003046306A1 (en)

Families Citing this family (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030163959A1 (en) * 2002-03-04 2003-09-04 Deming Joseph A. Insulated weather-resistant interlocking roof system and method
EP1570141B1 (en) * 2002-12-12 2011-01-12 Kingspan Research and Developments Limited Flat or substantially flat roof
US20050131368A2 (en) * 2003-03-04 2005-06-16 Diaperoos, Llc Vacuum-packed diaper
US7658040B2 (en) 2004-02-23 2010-02-09 Huber Engineered Woods Llc Panel for sheathing system and method
US11536028B2 (en) 2004-02-23 2022-12-27 Huber Engineered Woods Llc Panel for sheathing system and method
CA2619575A1 (en) * 2005-08-17 2007-02-22 Kingspan Research And Developments Limited A flooring system of sandwich-like floor elements having a core of insulating material
AU2006288688A1 (en) * 2005-09-06 2007-03-15 Kingspan Research And Developments Limited A roof system
GB2452391B (en) * 2007-08-27 2012-06-06 Kingspan Res & Dev Ltd A composite insulated roof panel
CA2777635C (en) 2009-10-16 2018-09-25 Kingspan Holdings (Irl) Limited A composite panel
ES2365773B1 (en) * 2009-11-27 2012-10-02 Asseteq S.C.P. BASE OF COVERS AND SIMILAR FOR CONSTRUCTION.
US9234355B2 (en) 2012-05-31 2016-01-12 Huber Engineered Woods Llc Insulated sheathing panel and methods for use and manufacture thereof
US10711453B1 (en) 2015-12-29 2020-07-14 Georgia-Pacific Panel Products Llc Building panel with a weather barrier

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4403980A (en) * 1973-02-27 1983-09-13 Star Manufacturing Company Of Oklahoma Prefabricated watertight structural system
GB8916262D0 (en) * 1989-07-15 1989-08-31 Allan Roofing Limited Roofing panel
FR2696202B1 (en) * 1992-09-25 1994-12-09 Haironville Sa Composite panel intended to constitute a roof or a building wall.
GB9824696D0 (en) * 1998-11-11 1999-01-06 Kingspan Building Products Lim A panel
DE19938014A1 (en) * 1999-08-11 2001-03-15 Thyssenkrupp Stahl Ag Building system for walls and roofs uses sandwich components with flat, or trapezoidal outer shell of metal, flat or profiled inner shell of metal and core of plastics, hard foam or mineral fibers

Also Published As

Publication number Publication date
WO2003046306A1 (en) 2003-06-05
US20050011155A1 (en) 2005-01-20
AU2002212526A1 (en) 2003-06-10
EP1442181A1 (en) 2004-08-04

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Legal Events

Date Code Title Description
EEER Examination request
FZDE Discontinued