DE8806670U1 - Insulating roof panel - Google Patents

Description

The invention relates to an insulating roof panel with a rigid foam plastic layer and with a cladding on the side which is on top after installation, hereinafter referred to as the top side, containing a perforated and a non-perforated layer, whereby these two layers are held together by the material of another layer which lies on one side against the perforated layer, and this material extends through the holes in the perforated layer and adheres to the non-perforated layer which lies against the opposite side of the perforated layer.

An insulating roof panel of the aforementioned type is known from US-A-4,136,223.

The cladding of the top of a foam plastic core in this well-known roof panel consists of a perforated glass fiber foil glued to the core, a layer of stones or pebbles on the top of the same and a top layer of a bituminous roof covering material.

Although according to the aforementioned US patent US-A-4,136,223, the top layer is only partially connected to the glass fiber foil by means of the stone or pebble layer through the foam plastic of the core penetrating through the holes in the glass fiber foil, thereby preventing the formation of bubbles, the stone or pebble layer is not completely impermeable to the possibly softened or liquefied bitumen of the top layer.

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The stones (pebbles) form a covering for the roof covering material and must therefore not be left completely loose. They are partially embedded in the roof covering material. This means that the thickness of the stone layer is limited to the thickness of a stone or pebble and therefore gaps remain between the stones, through which the bitumen of the roof covering material can penetrate if it is liquid enough.

The bitumen can already obtain sufficient flowability when the foamed plastic is foamed, if this plastic is polyurethane, for example, due to the fact that this foaming has an exothermic reaction process.

Under the influence of the heat released during welding of the bituminous top layer or the heat of the sun, the bitumen becomes sufficiently soft and fluid to pass through the layer of stones.

to penetrate, especially when, for example,

, when entering the roof there is sufficient pressure

&xgr; is exerted on the upper layer.

With these well-known roof tiles, the bituminous coating can be removed during production or after some time.

f upper class untti the influence of the sun's heat almost

r over its entire surface on the perforated glass fiber

stick the film, which can cause bubbles to form.

The same disadvantage also applies to the insulating roof panel

according to FR-A-2.526.463. The insulating roof pi« according to this publication is self-supporting like the aforementioned known roof panels and has a rigid foam plastic core, the underside of which is covered with a rigid

- 3 -layer clad.

The top cladding of the core consists of a layer of fibrous material, for example a polyester layer, the outside of which is covered with a layer of bitumen.

The gas diffusion now does not take place between two cladding layers which are arranged loosely from each other, but within the fiber material layer itself.

Under the influence of the heat released during welding from the bituminous top layer or the heat of the sun, the bitumen can gradually penetrate into this fibrous material layer, whereby the gas diffusion in this layer is greatly reduced and thus blistering can occur.

The purpose of the present invention is to provide a practical solution to the aforementioned problems and to create an insulating roof panel of the type defined above, which is characterized by a particularly simple construction and an absolutely reliable elimination of the risk of blistering, even long after the roof panel has been installed.

For this purpose, the top layer of the two aforementioned cladding layers contains a film which is in itself bitumen-free and which is absolutely impermeable to softened or liquefied solid bitumen or similar substances used in roof cladding materials and which retains this property, i.e. its impermeability to bitumen or similar substances, even at the liquefaction temperature of the solid bitumen or similar substances.

does not lose its shape, whereby this upper layer in the areas outside the holes is completely loose from the lower layer of the two layers of roof cladding glued to the foam plastic layer.

According to a special embodiment of the invention, the foam plastic layer is also provided on the underside with a covering which contains a film which touches the foam plastic layer and which behaves during foaming and hardening of the same and during humidity and temperature fluctuations in a similar way to the lower layer of the covering of the upper side of the foam plastic layer, which also contains a film which touches the foam plastic layer.

This prevents the plate from warping during production and afterwards due to humidity and temperature fluctuations, which not only prevents the formation of bubbles, but also gives the plate greater stability.

The foam plastic core is enclosed between two films that behave similarly, i.e. that do not bend the core. The other layers of the cladding on the top of the core do not affect this stability, since the layer on the top of the lower film glued to the core is only attached to this lower film in places at most.

According to one embodiment of the present invention, the perforated layer is located on the top of the non-perforated layer, this non-perforated layer is gas-permeable, the perforated layer outside the holes is impermeable to softened or liquefied solid bitumen or similar substances, and the layer whose material extends through the holes of the

The

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perforated layer, a bituminous or similarly composed layer on top of the perforated layer, the material of which adheres to the non-perforated layer through the holes.

According to another embodiment of the invention, the perforated layer is, however, the lower covering layer of the upper side of the foam plastic layer, this perforated layer is gas-permeable and the layer whose material extends through the holes of the perforated layer is the foam plastic layer, whose material adheres to the non-perforated layer through the holes.

The ^layer impermeable to softened or liquefied solid bitumen may be a composite layer, such as an aluminium-glass fibre composite layer, or a simple layer, such as a "coated" glass fibre sheet.

According to a preferred embodiment of the invention, the holes in the perforated layer occupy 5-50% of the surface of the same.

Further characteristics and advantages of the invention will become apparent from the following detailed description of an insulating roof panel according to the invention.

This description, given purely by way of example and without any limiting intention, is made with reference to the accompanying drawings, in which the reference numbers of the description correspond to those of the figures and

Figure 1 is a perspective view of a partial

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wise cut-off roof panel according to the invention ;

Figure 2 shows a roof panel according to Figure 1 in cross-section;

Figure 3 shows a perspective view similar to Figure 1 of a part of an insulating roof panel according to another embodiment of the invention ;

Figure 4 shows a cross-section of part of the roof cladding according to Figure 3 on an enlarged scale;

Figure 5 shows schematically a device for manufacturing the insulating roof panel according to Figures 3 and 4;

Figure 6 shows a perspective view similar to Figures 1 and 3 of a part of an insulating roof panel according to a further embodiment of the invention; and

Figure 7 shows a cross-section of the part of the roof panel according to Figure 6 on an enlarged scale.

In all figures, the reference numbers refer to the same elements.

The insulating roof panel according to Figures 1 and 2 has a hard polyurethane core 1, the upper side of which is covered with a covering consisting of

v- from a non-perforated, over the entire surface of the

Core 1 bonded, gas-permeable Giffj fiber film 2,

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a "coated" one with holes 4, on
the top of the glass fibre foil 2 without adhesive
arranged for softened or liquefied solid bitumen or similar used in roof cladding
Materials outside the holes 4 impermeable glass fibre foil 3, and one made of solid bitumen or similar materials,
such as elastomers or elastomer-bitumen wipes, existing outer or upper layer 5.

The material of the upper layer 5 extends through |

the holes 4 of the glass foil 3 through to the glass foil \

2, to which it sticks. The upper layer 5 is
Material, ie with bitumen or similar substances,
the lower layer 2 and consequently at the layer
1. This material therefore provides the
Bitumen impermeable middle layer made of "coated"
Glass fibre foil 3 in the area of the holes 4 in place and

Place held. \

The term "coated" glass fibre film refers
here on a with sound or another suitable .j

Material: glass fiber foil soaked in water. This treatment increases the permeability of the glass fiber foil to such an extent that
reduced so that they are gas-permeable but impermeable, for example, to softened or liquefied
Solid bitumen. The impermeability thus obtained is also maintained at temperatures where solid bitumen becomes liquid. J

This treatment also increases the stability of the |

Foil, so that the glass fiber foil 2 is also "coated" /

can be. %

The lower glass fibre foil 2 adheres to the foam plastic core 1 either by the foam plastic being

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indirectly sprayed onto this glass fiber film 2 and foamed there, or by the film 2 being glued to the foam plastic layer using an adhesive, preferably over its entire surface.

The underside of the foam plastic core 1 is also covered, but now with a film 6, preferably consisting of a material that behaves similarly to the layer formed by the glass fiber film 2 when the foam plastic foams and hardens or when there are fluctuations in humidity and temperature and is therefore preferably also a glass fiber film.

Since the foam plastic core 1 is covered on both sides with a layer that behaves similarly when foaming and hardening the core 1, which are the glass fiber foils 2 and 6, the glass fiber foil 3 is loose from the glass fiber foil 2 and the upper layer 5 is only glued to the glass fiber foil 2 in places in the area of the holes, the panel has great stability and, above all, its tendency to warp is eliminated.

The holes 4 of the glass fiber foil 3 take up 5-50%, preferably about 15%, of its surface, so that sufficient space remains for any gas diffusion between the glass fiber foils 2 and 3.

The glass fibre foil 3 of the cladding 2,3 on the upper side of the foam plastic layer 1 is heat-resistant in contact with solid bitumen liquefied by heat and does not lose its impermeability to such solid bitumen liquefied at the temperatures in question. At these temperatures the glass fibre foils 2 and 3 do not have the slightest tendency to stick together and the bitumen is not able

- 9 to seep through the glass fibre foil 3.

Due to the possibility of gas spreading between the glass fibre foils 2 and 3, the formation of bubbles in the cladding is expediently avoided, even later after the roof panel has been installed.

The top layer 5 containing solid bitumen or similar materials can also be finished with a so-called burn-away film 7. This film 7 prevents the layer 5 from sticking to other materials or roof panels. It is burned away when the upper roof cladding layer is finally burned onto the roof panels, which of course have the layer 5 on top.

According to a variant of the embodiment of the invention described in the previous lines, the perforated layer itself is composed of a glass fiber film underneath and an aluminum layer on top, which is a so-called aluminum-glass fiber composite material. The aluminum layer is a film that is absolutely impermeable to bitumen.

The embodiment according to Figures 3 and 4 differs essentially from the embodiment described above in that the perforated glass fiber foil 3 and the non-perforated glass fiber foil 2 are mixed up and the foam plastic of the core 1 extends through the holes in the glass fiber foil 3 and sticks to the glass fiber foil 2 in places, so that the glass fiber foils 2 and 3 are completely loose from each other outside the holes.

As a result, the use of a special layer to hold foils 2 and 3 together is unnecessary, so that

-10-&iacgr;' * the upper part is simply omitted in the embodiment according to Figures 3 and 4.

Now that the unperforated glass fibre foil 2 is completely

U must be impermeable to softened or liquefied

Plague biturns, originating from the after laying of the

yes roof panels arranged bitumen cladding, this must

Fiberglass foil 2 "coated" leg, while the perforated

~i Cläöfäserfolie 3 certainly gas permeable j but not

'■' must necessarily be impermeable to bitumen.

The glass fibre foil 3 does not necessarily need a

"coated" glass fiber foil, but must

:| Similar behavior during foaming and curing

of the foam plastic of the core 1 and in the case of humidity and temperature fluctuations such as the layer 6 covering the underside of the core 1 and guaranteeing the required stability of the roof panel.

In this embodiment, the "coated" glass fiber foil 2, which is impermeable to bitumen, can also be replaced by a composite layer containing a layer that is absolutely impermeable to bitumen, so that an aluminum-glass fiber composite material can also be used here.

The roof panel ^^ss of the last-mentioned design can be easily commercialized. Such roof panels are then installed on the roof with one or more bituminous roof coverings.

covered with tissues.

According to a variant of this embodiment, if possible, as illustrated in Figures 6 and 7, the roof slab is provided in advance with a bituminous layer 8, which is preferably applied to the upper side

; -limit of a burn-away foil omitted from Figures 6 and 7 for convenience.

The design of the roof panel according to Figures 6 and 7 also differs from the design according to Figures 3 and 4 in that the "coated" glass fiber foil 2 is replaced by a conventional glass fiber foil 9, which is made impermeable to softened or liquefied solid bitumen by means of a polyethylene or polypropylene film 10 located on the side of the core 1.

This polyethylene layer will not stick to the perforated glass fibre foil 3 at the liquefaction temperature of the bitumen.

For the finishing of the roof panel according to the pictures

3 and 4, a system of the type illustrated in Figure 5 is suitable.

As can be seen from Figure 5, the hole-pierced

4 provided glass fibre foil 3 from a first roll

11, while the glass fiber film 2 is unwound from a neighboring roll 12 and the two films are guided over the underside of the rolls 13.

The glass fiber foil 6 is unwound from a roll 14 arranged under the rolls 11 and 12 and guided over the top of a set of rolls 15. Polyurethane is sprayed through the spray nozzles 16 between the mainly horizontal glass fiber foils 3 and 6. The foam swelling between the foils 3 and 6 penetrates into the holes 4 up to the glass fiber foil 2. After the foam has hardened, the continuous strip material is cut into sheets of the desired length '3. *j

The roof panel according to Figures 6 and 7 is manufactured in a similar way using the same system, but the simple glass fiber foil 2 unwound from the roll 12 is replaced by a prefabricated composite layer, consisting of the film 10, the glass fiber foil 9 and the bituminous top layer 8.

When manufacturing the roof panel according to Figures 1 and 2, a polyurethane foam is allowed to foam up and harden between the foil 6 and a composite layer, whereby this composite layer consists of the foil 2, the perforated foil 3, the bitumen layer 5 and the burn-off layer 7, which are connected to one another during production.

The roof panels described in the previous lines are flat and stable and are suitable for simple and quick production.

In order to produce a roof covering, a layer consisting of such panels is arranged on a supporting base, naturally with the glass fibre foil 6 below and the cladding 2,3; 2,3,5,7 or 3,10,9,8 above, and then one or more layers of a bituminous roof covering material are usually glued onto this layer of panels.

The formation of bubbles in the roof covering is absolutely impossible when using such roof panels.

The invention is by no means limited to the embodiments described above, but is susceptible, within the scope of the invention, to a wide variety of modifications and additions to the same with regard to the form, composition, arrangement and number of elements used in the application of the invention.

⁶ ·

- 13 ^f In particular, the materials of the various

Layers are only mentioned for illustrative purposes.

The core is not necessarily a foam polyurethane core.

Other foam plastics, such as polyisocyanurate and the like, are also suitable for use as core material.

Instead of glass fiber foils, other mineral foils and even organic fiber foils are also suitable for use in the roof panels according to the invention, provided they meet the following conditions: the layer adjacent to the core must be gas-permeable; the layer lying on top of it must be impermeable to softened or liquefied solid bitumen; these two layers must not stick together at the liquefaction temperature of the bitumen.

Claims (13)

EXPECTATIONS Insulating roof panel with a rigid foam plastic layer (1) and with, on the side of the latter which is on top after laying, hereinafter referred to as the top, a covering (2,3 or 2,3,5 or 2,3,8) containing a perforated layer (3) and a non-perforated layer (2), whereby these two layers (2 and 3) are held together by the material of a further layer (1 or 5) lying on one side against the perforated layer (3), and this material extends through the holes (4) of the perforated layer (3) and adheres to the non-perforated layer (2) lying against the opposite side of the perforated layer (3), characterized in that the upper layer (3 or 2) of the two aforementioned layers (2 and 3) has a s ■··· mm mm &igr; »··· rm mm Contains a film which does not contain bitumen in itself and is also absolutely impermeable to liquefied or softened solid bitumen or similar materials used in roof coverings and does not lose this property, i.e. its impermeability to bitumen or similar materials, at the liquefaction temperature of the solid bitumen or similar materials, whereby this upper layer (3 or 2) is completely separate in its areas outside the holes from the lower layer (2 or 3) of the two layers (2 and 3) of the roof covering (2,3 or 2,3,5 or 2,3,8) glued to the plastic layer (1). 2. Insulating roof panel according to claim 1, characterized in that the foam plastic layer (1) is also provided on its underside with a covering which contains a film (6) lying against the foam plastic layer (1), which when foaming and hardening the foam plastic layer (1) and in the event of humidity and temperature fluctuations behaves in a similar way to the lower layer (2 or 3) of the covering (2,3; 2,3,5 or 2,3,8) of the upper side of the foam plastic layer (1) containing a film lying against the foam plastic layer (1). 3. Insulating roof panel according to one of the preceding claims 1 and 2, characterized in that the perforated layer (3) is located on the upper side of the non-perforated layer (2), this non-perforated layer (2) is gas-permeable, the perforated layer (3) outside the holes (4) is impermeable to Ii softened or liquefied solid bitumen or other ill similar substances, and the layer (5) whose material through the holes (4) of the perforated layer I (I It Mil Il ■ · IIII · ■ · 1*1 I I I (3) extends through, a layer containing solid bitumen or similar substances located on the upper side of the perforated layer (3) (5), the material of which adheres to the non-perforated layer (2) through the holes (4). 4. Insulating roof panel according to claim 3, characterized in that the unperforated lower layer (2) of the cladding (2, 3, 5) is glued to the rigid foam plastic layer (1) with an adhesive. 5. Insulating roof panel according to claim 3, characterized in that the unperforated lower layer (2) of the cladding (2, 3, 5) is glued to the rigid foam plastic layer (1) by being arranged on the same according to the spraying process. 6. Insulating roof panel according to one of the claims 1 and 2, characterized in that the perforated layer (3) is the lower layer of the covering (2,3 or 2,3,8) of the upper side of the foam plastic layer (1) and is gas-permeable, and the layer whose material extends through the holes (4) of the perforated layer (3) is the foam plastic layer (1) whose material extends through the holes (4) adheres to the non-perforated layer (2). 7. Insulating roof panel according to claim 6, characterized in that the upper non-perforated layer (2) of the two layers of cladding (2,3 or 2,3,8) the upper side of the foam plastic layer (1) is provided with a bitumen layer (8). 8. Insulating roof panel according to any one of the claims • · · a I If · · ···· · · I'll it , , 3-5 and 7, characterized in that the bitumen layer (5 or 8) lying on the upper side of the cladding (2,3,5 or 2,3,8) of the foam plastic layer (1) is finished on its upper side by coating with a burn-off film (7). 9. Insulating roof panel according to any one of claims 1-8, characterized in that the lower layer (2 or 3) of the cladding (2,3; 2,3,5 or 2,3,8) of the upper side, lying against the foam plastic layer (1), is made of glass fiber foil. 10. Insulating roof panel according to claim 9, characterized in that the lower layer (2 or 3) lying against the layer (1) is made of "coated" glass fiber foil. 11. Insulating roof panel according to any one of claims 1-10, characterized in that the upper layer (2 or 3) impermeable to liquefied or softened solid bitumen is an aluminum-glass fiber composite foil. 12. Insulating roof panel according to any one of claims 1-10, characterized in that the upper layer (2 or 3) impermeable to liquefied or softened solid bitumen is a "coated" glass fiber foil. 13. Insulating roof panel according to any one of claims 1-12, characterized in that the holes (4) of the perforated layer (3) occupy 5-50% of the surface of this layer (3).