EP0039158A2 - Insulating foam building panel and method of construction utilizing such panels - Google Patents
Insulating foam building panel and method of construction utilizing such panels Download PDFInfo
- Publication number
- EP0039158A2 EP0039158A2 EP81301563A EP81301563A EP0039158A2 EP 0039158 A2 EP0039158 A2 EP 0039158A2 EP 81301563 A EP81301563 A EP 81301563A EP 81301563 A EP81301563 A EP 81301563A EP 0039158 A2 EP0039158 A2 EP 0039158A2
- Authority
- EP
- European Patent Office
- Prior art keywords
- heat insulating
- panels
- roofing
- layer
- 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.)
- Withdrawn
Links
- 238000010276 construction Methods 0.000 title claims abstract description 15
- 238000000034 method Methods 0.000 title claims abstract description 10
- 239000006260 foam Substances 0.000 title description 7
- 239000000463 material Substances 0.000 claims abstract description 78
- 239000006261 foam material Substances 0.000 claims abstract description 32
- 230000005855 radiation Effects 0.000 claims abstract description 17
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 claims abstract description 12
- 230000001681 protective effect Effects 0.000 claims description 31
- 239000000853 adhesive Substances 0.000 claims description 19
- 230000001070 adhesive effect Effects 0.000 claims description 19
- 239000011087 paperboard Substances 0.000 claims description 14
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 10
- 229910052782 aluminium Inorganic materials 0.000 claims description 10
- 239000011888 foil Substances 0.000 claims description 9
- 239000010426 asphalt Substances 0.000 claims description 6
- 229920001084 poly(chloroprene) Polymers 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 description 6
- 239000000123 paper Substances 0.000 description 5
- 239000002131 composite material Substances 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 4
- 239000004033 plastic Substances 0.000 description 3
- 229920003023 plastic Polymers 0.000 description 3
- 229920005989 resin Polymers 0.000 description 3
- 239000011347 resin Substances 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 239000004793 Polystyrene Substances 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 239000002655 kraft paper Substances 0.000 description 2
- 239000012528 membrane Substances 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 238000009435 building construction Methods 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000011437 continuous method Methods 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 238000005187 foaming Methods 0.000 description 1
- SLGWESQGEUXWJQ-UHFFFAOYSA-N formaldehyde;phenol Chemical compound O=C.OC1=CC=CC=C1 SLGWESQGEUXWJQ-UHFFFAOYSA-N 0.000 description 1
- ZZUFCTLCJUWOSV-UHFFFAOYSA-N furosemide Chemical compound C1=C(Cl)C(S(=O)(=O)N)=CC(C(O)=O)=C1NCC1=CC=CO1 ZZUFCTLCJUWOSV-UHFFFAOYSA-N 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- 238000005192 partition Methods 0.000 description 1
- 229920001568 phenolic resin Polymers 0.000 description 1
- 239000011496 polyurethane foam Substances 0.000 description 1
- 229920002689 polyvinyl acetate Polymers 0.000 description 1
- 239000011118 polyvinyl acetate Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000009418 renovation Methods 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 230000008961 swelling Effects 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
- E04D3/35—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation
- E04D3/357—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation comprising hollow cavities
-
- 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
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
- E04D3/35—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation
- E04D3/351—Roofing 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
- E04D3/352—Roofing 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
Definitions
- the present invention relates to heat insulating panels which are comprised of a core of foam material for use in construction of heat insulated building structures, such as built-up roofs, and more particularly to an improved heat insulating panel which manifests reduced curling under the heat of the sun.
- foamed plastic material for insulating purposes in building structures such as exterior or partition walls, bulk heads, ceilings, floors, storage tanks, and roof structures is well known as such foamed plastic materials have a very low thermal conductivity.
- foam plastic materials having low thermal conductivity for instance may comprise phenolic foam material such as for example thermoset phenol formaldehyde materials.
- phenolic foam material employed in a roofing structure is disclosed in U.S. Patent 4227356.
- Other low thermal conductivity foam materials may comprise poly-styrene foam and/or urethane foam.
- the foam materials used as roofing insulation have a density of about 1.5 to about 6 lb/ft 3 so as to have sufficient strength to support persons and their equipment.
- the foam 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 of making the heat insulating panels, as well as to protect and maintain the integrity of the sandwiched foam material.
- roofing panels One problem experienced with respect to such heat insulating panels of the prior art, such as roofing panels, is curling or warping of the panel. More particularly, during the construction of built-up roofs employing such heat insulating roofing panels, the insulation panels are initially applied with a suitable adhesive to the supporting structure, such as for example a corrugated steel roof deck, and then bituminized roofing materials are applied over roof insulator panels to complete the roof structure. However, from the time the panels are applied on the roof support structure until the application of roofing materials thereover, the panels curl under the heat of the sun. For example, with two inch thick roofing panels constructed of open celled phenolic foam material sandwiched between a pair of paper media, curling of up to one inch can result under the heat of the sun on a very hot day.
- the improved heat insulating panel comprises first and second oppositely disposed surfaces having a core therebetween comprised of heat insulating foam material.
- One of the oppositely disposed surfaces includes a thin layer of reflecting material over substantially the entire surface thereof to reduce the heat conveyed to the core due to sun radiation when the insulating panel is exposed to sun radiation duringthe construction or the renovation of a building structure.
- foam materials such as phenolic foam materials, which meet the mechanical and heat insulating performance requirements for building structures
- the foam materials have a tendency to retain moisture which, given enough time, reaches equilibrium with the atmospheric vapor partial pressure.
- foam materials may have the characteristic of absorbing and retaining up to 10% moisture by weight when in an environment at 50% relative humidity at room temperature.
- the sun radiation may heat up the exposed surface of the panel.
- the resulting heat gradient established in the panel in turn may have the tendency to drive the moisture in the panels from the hot side of the panel to the relatively cool side of the panel, thereby causing shrinkage of the top exposed side of the panel and swelling and/or expansion of the lower side of the panel. This can thus result in the aforementioned curling problem experienced in the prior art.
- the heat insulating panels are adhered to the supporting structure.
- the sun radiation is reflected away from the core of foam material, so that the temperature differential across the panel is reduced. Consequently, warpage or curling of the panels is substantially reduced so that the finishing materials such as roofing materials when the panels are supported on a roof support structure, may be easily applied over the surface of the heat insulating panels.
- the thin layer of reflecting material comprises a thin layer of aluminum foil on the one surface of the panel.
- the core of foam material is sandwiched between a pair of protective skins, each of which may comprise a corrugated medium of kraft, semi-chemical or similar paper having a liner attached to one side thereof remote from the core.
- the aluminum foil is adhesively secured to the liner of one of the protective skins so as to substantially overlie one of the outer surfaces of the panel.
- the thin layer of aluminum foil may be secured with a neoprene adhesive or other high wet strength adhesive.
- a method of constructing a heat insulating structure which comprises of the steps of providing a plurality of heat insulating panels, each of which includes a thin layer of reflecting material over substantially the entire surface of one side of the panel, applying the plurality of heat insulating panels on a building support structure so that the layer of reflecting material on the first surfaces is exposed to the sun radiation which may be present, whereby the thin layer of reflecting material serves to reduce heat conveyed to the core of the panel when sun radiation is present, and then applying at least one layer of finishing material over the supported panels to thereby substantially cover the reflecting material. In this way, the problem of warping or curling of the panels prior to the application of the finishing material thereover is minimized.
- the protective skin 12 preferably comprises a single faced corrugated paper board structure having a corrugated paper board medium 14 and an outer liner 16 adhered to the crest portions of the corrugated medium with a suitable adhesive, such as for example a wet strength adhesive.
- a thin layer of reflecting material 20, which may for example comprise a thin sheet of aluminum foil, is in turn adhesively secured to the outer surface of the liner 16, i.e., the surface opposite to the surface adhered to the crest portions of the corrugated medium 14.
- the composite protective skin 12 may be provided with a plurality of pre-perforations 22 which pass through the corrugated medium 14, the paper board liner 16 and the thin layer of reflecting material 20, for a purpose to be explained more fully hereinbelow.
- FIG 2 a heat insulating panel 10 in accordance with the present invention which is particularly useful as a roofing panel for construction of a built-up roof.
- the panel 10 comprises upper and lower protective skins 12, 13 having a core 24 of foam material therebetween such as for example phenolic foam material which is dimensionally moisture sensitive.
- the upper protective skin 12 comprises a skin such as shown in Figure 1 having a thin layer of reflecting material 20 thereon, whereas the lower protective skin 13 is of a similar construction to the upper skin 12 with the exception that no layer of reflecting material need be provided.
- the thin layer of reflecting material 20 need only be provided on one of the outer surfaces of the formed heat insulating roofing panel 10, i.e., on the surface of the corrugated paper board facing away from the corrugated medium 14 and also away from the core 24 of the phenolic foam material therebetween.
- the upper and lower protective skins 12, 13 both preferably comprise single faced corrugated skins which provide for a good adhesion between skins 12, 13 and the phenolic foam material 24 therebetween as a result of the reduction of the amount of volatile materials accumulated between the skins 12, 13 during the manufacturing process and of the foamable resin compound passing through the plurality of pre-perforations 22 provided therein.
- This feature is more fully disclosed in U.S. Patent 4227356, which is hereby incorporated by reference, and which discloses that a good bond strength between the foam core 24 and the corrugated protective skins 12, 13 is provided.
- the heat insulating board or panel 10 may be provided with a plurality of post-perforations 26 which provide for an increased bond between the core 24 of the foam, the protective skins 12, 13 and the roof supporting structure 30 on one side of the heat insulating roofing panel 10 and the finishing roofing membrane 32 on the other side thereof by means of the roofing adhesive 34 and the roofing bitumen 26 which penetrates through the post- perforation holes during the process of forming the resulting roofing structure 40 (see Figure 3).
- the roofing material (either the roofing adhesive 34 for securing the panels 10 to the roof supporting structure 30 or the bitumen 36 applied over the upper surface of the roofing panels 10 during the construction of the roof 40) will seep through the post-perforations 26 and form plugs 28 which provide a firm water resistant bond between the roofing materials and the heat insulating roofing panel or board 10.
- a plurality of the heat insulating roofing panels 10 such as shown in Figure 2 are placed on a suitable roof supporting structure 30, which may for example comprise a corrugated sheet steel support, the crests or peaks of which serve to support the roofing panels 10.
- a suitable roof supporting structure 30 which may for example comprise a corrugated sheet steel support, the crests or peaks of which serve to support the roofing panels 10.
- the roofing panels 10 are arranged in side by side relationship to cover the entire upper surface of the corrugated support structure 30.
- Each of the panels 10 is arranged so that the thin layer of reflecting material 20 provided on the outer surface of one of the sides of the panels 10 faces away from the roof supporting structure 30, i.e., to face upwardly as shown in Figure 3.
- the thin layer 20 of reflecting material will be exposed to any sun radiation which is present during this phase of the construction of the roof.
- Each of the roofing panels 10 may be suitably secured to the corrugated roof supporting structure 30 with any suitable adhesive 34, such as for example by roofing adhesive which may penetrate the bottom protective skin 13 through the post-perforations 26. This will form the aforementioned plugs 28 in the lower side of the panel 10.
- any suitable adhesive 34 such as for example by roofing adhesive which may penetrate the bottom protective skin 13 through the post-perforations 26. This will form the aforementioned plugs 28 in the lower side of the panel 10.
- roofing materials may comprise bituminous roofing materials such as alternating layers of asphalt 36, and asphalt saturated roofing felts 38, with the system then being gravelled over to complete the finished roof structure 40. In the embodiment shown in Figure 3, four layers each of asphalt 36 and 38 are shown. However, if desired, fewer or more layers could be provided.
- prior art heat insulating roofing panels constructed of foam material have experienced problems in curling or warpage. This is believed in part to be due to the fact that the foam material has a tendency to absorb and retain moisture. For example, the foam materials may have a tendency to absorb approximately 10% moisture by weight when in an environment at 50% relative humidity at room temperature.
- the heat from the sun radiation on the upper surface of the panels can cause a high temperature differential across the opposite surfaces which can have the effect of driving the moisture in the foam material away from the hot side towards the cold side, and/or uneven evaporation of the moisture therewithin.
- the roofing panels 10 are provided with a thin layer 20 of reflecting material on the outer upper surface thereof, the effects of curling are greatly reduced. It is believed that this is the result of the fact that the thin layer 20 of reflecting material serves to reflect and direct the sun radiation away from the upper surface of the heating panel 10 before the application of the roofing material 36, 38 and thereby results in a decrease in the temperature differential across the thickness of the panels 10.
- the thickness being below .001 inches, for ex- , ample on the order of .00035 inches
- the amount of curling experienced in a two inch thick roofing panel 10 has been reduced to below 3/8 inch and in most instances to 1/4 inch or less.
- the layer 20 of reflecting material is adhered to the liner 16 of corrugated paper board 12 or other material utilized as the protective skin of the roofing panel 10 by means of a high wet strength adhesive.
- wet strength adhesive it should be understood that any adhesive which maintains the bond between the liner 16 and the layer 20 of reflecting material over a long period of time of water immersion, can be employed.
- suitable wet strength adhesive may comprise thermosetting polyvinyl acetate based adhesive as well as neoprene adhesives.
- the same types of adhesive may also be utilized in adhesively securing the liner 16 to the corrugated medium 14.
- the thin layer 20 of reflecting material in accordance with the present invention, is preferably adhesively secured to the corrugated paper board 12 or other medium prior to the use of the paper board medium 12 in the manufacturing of the heating panels 10.
- the thin layer 20 of reflecting material is preferably initially laminated to the corrugated paper board 12 in the preferred embodiment to form a protective skin 12 prior to the manufacture of the heating panel 10 and the use of the protective skin 12 in such manufacturing process.
- the manufacture of the panels 10 will be in accordance with a continuous method similar to that described for example in U.S. Patent No. 3,821,337 to Bunclark, issued January 28, 1974, which reference is herebyincorpor- ated by reference in its entirety.
- U.S. Patent No. 3,821,337 not only describes a continuous process for the manufacture of heat insulating panels but also describes resins which may be employed therein.
- the present invention could be employed with other types of foam materials which are dimensionally thermo - or hydro - sensitive, such as for example some poly-styrene or urethane foams, in order to minimize curling or warping of the heat insulating panels.
- the density of the resulting core 24 of open celled phenolic foam material is generally in the range of about 1.5 to 6.0 lb./ft3 and preferably about 2 to 3.5 lb./ft 3 .
- the preparation of the resin and its foaming are well known in the chemical art as well as the roofing art and needs no further elaboration herein. Examples of such materials can be found in U.S. Patent Nos. 3,741,920, 3,726,708, 3,694,387, 3,779,956, 3,877,967, and 3,953,645.
- single faced corrugated paper board be used, since such material is generally less costly in comparison to other suitable materials.
- suitable single faced corrugated paper board may for example include a liner and medium of kraft, semi-chemical or other similar paper material. Typical weights for such paper board may range from about 26 lb./l000 ft 2 to about 42 lb./1000 ft ; however, it should be understood that other weights for the paper board could be utilized.
- pre-perforations 22 and post-perforations 26 are provided in the protective skins 12, 13, (in accordance with the principles of the aforementioned Patent 4,227,356), it will be appreciated that use of such perforations 22, 26 is not necessary, as a wide variety of types and configurations of protective skins 12, 13 could be used in combination with a thin layer 20 of highly reflective material adhesively secured to the outer surface thereof.
- the layer of reflecting material preferably comprises a thin layer 20 of aluminum foil
- the layer of reflecting material preferably comprises a thin layer 20 of aluminum foil
- other types of highly reflective materials could also be utilized which would serve to reflect and direct sun radiation away from the upper surface of the panel when same is supported on a building structure.
- Such highly reflective material should preferably have an emissivity of less than 0.30, and more preferably less than 0.10.
- Aluminum foil has an emissivity of approximately 0.05.
- Another suitable material may for example comprise a very thin layer of gold.
- the layer of aluminum has a thickness of less than 0.001 inches and preferably on the order of .00035 inches, other thicknesses may of course be used. Themain consideration in this regard may be the cost of such materials.
- the major requirement on the thickness of the highly reflective material is whether the material may be adhesively secured to the protective skin medium.
Abstract
Description
- The present invention relates to heat insulating panels which are comprised of a core of foam material for use in construction of heat insulated building structures, such as built-up roofs, and more particularly to an improved heat insulating panel which manifests reduced curling under the heat of the sun.
- The use of foamed plastic material for insulating purposes in building structures such as exterior or partition walls, bulk heads, ceilings, floors, storage tanks, and roof structures is well known as such foamed plastic materials have a very low thermal conductivity. Such foam plastic materials having low thermal conductivity for instance may comprise phenolic foam material such as for example thermoset phenol formaldehyde materials. One example of such use of phenolic foam material employed in a roofing structure is disclosed in U.S. Patent 4227356. Other low thermal conductivity foam materials may comprise poly-styrene foam and/or urethane foam.
- The foam materials used as roofing insulation have a density of about 1.5 to about 6 lb/ft3 so as to have sufficient strength to support persons and their equipment.
- Typically, in such construction applications, the foam 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 of making the heat insulating panels, as well as to protect and maintain the integrity of the sandwiched foam material.
- One problem experienced with respect to such heat insulating panels of the prior art, such as roofing panels, is curling or warping of the panel. More particularly, during the construction of built-up roofs employing such heat insulating roofing panels, the insulation panels are initially applied with a suitable adhesive to the supporting structure, such as for example a corrugated steel roof deck, and then bituminized roofing materials are applied over roof insulator panels to complete the roof structure. However, from the time the panels are applied on the roof support structure until the application of roofing materials thereover, the panels curl under the heat of the sun. For example, with two inch thick roofing panels constructed of open celled phenolic foam material sandwiched between a pair of paper media, curling of up to one inch can result under the heat of the sun on a very hot day.
- It is desirable to minimize the amount of curling before the application of roofing materials thereon, in order to assure a reasonably flat support on which the components of the roofing membrane can be applied.
- In accordance with the present invention, there is provided an improved heat insulating panel, such as for example a roofing panel or an insulating sheathing panel, which manifests reduced curling or warpage of the panel after being applied on a supporting structure and before application of finishing materials thereover, and as such overcomes some of the above discussed and other disadvantages of the prior art. More particularly, in accordance with the present invention, the improved heat insulating panel comprises first and second oppositely disposed surfaces having a core therebetween comprised of heat insulating foam material. One of the oppositely disposed surfaces includes a thin layer of reflecting material over substantially the entire surface thereof to reduce the heat conveyed to the core due to sun radiation when the insulating panel is exposed to sun radiation duringthe construction or the renovation of a building structure.
- In this regard, with many suitable foam materials, such as phenolic foam materials, which meet the mechanical and heat insulating performance requirements for building structures, the foam materials have a tendency to retain moisture which, given enough time, reaches equilibrium with the atmospheric vapor partial pressure. For example, such foam materials may have the characteristic of absorbing and retaining up to 10% moisture by weight when in an environment at 50% relative humidity at room temperature.
- Consequently, when the heat insulating panels are exposed to sun radiation after being applied to a supporting structure and before application of the finishing materials thereover, the sun radiation may heat up the exposed surface of the panel. The resulting heat gradient established in the panel in turn may have the tendency to drive the moisture in the panels from the hot side of the panel to the relatively cool side of the panel, thereby causing shrinkage of the top exposed side of the panel and swelling and/or expansion of the lower side of the panel. This can thus result in the aforementioned curling problem experienced in the prior art.
- However, with the present invention, during the construction of the building structure, the heat insulating panels are adhered to the supporting structure. In this manner, the sun radiation is reflected away from the core of foam material, so that the temperature differential across the panel is reduced. Consequently, warpage or curling of the panels is substantially reduced so that the finishing materials such as roofing materials when the panels are supported on a roof support structure, may be easily applied over the surface of the heat insulating panels.
- More particularly, and in accordance with the preferred embodiment, the thin layer of reflecting material comprises a thin layer of aluminum foil on the one surface of the panel. Still more particularly, the core of foam material is sandwiched between a pair of protective skins, each of which may comprise a corrugated medium of kraft, semi-chemical or similar paper having a liner attached to one side thereof remote from the core. The aluminum foil is adhesively secured to the liner of one of the protective skins so as to substantially overlie one of the outer surfaces of the panel. For example, the thin layer of aluminum foil may be secured with a neoprene adhesive or other high wet strength adhesive.
- In accordance with another aspect of the present invention, there is disclosed a method of constructing a heat insulating structure which comprises of the steps of providing a plurality of heat insulating panels, each of which includes a thin layer of reflecting material over substantially the entire surface of one side of the panel, applying the plurality of heat insulating panels on a building support structure so that the layer of reflecting material on the first surfaces is exposed to the sun radiation which may be present, whereby the thin layer of reflecting material serves to reduce heat conveyed to the core of the panel when sun radiation is present, and then applying at least one layer of finishing material over the supported panels to thereby substantially cover the reflecting material. In this way, the problem of warping or curling of the panels prior to the application of the finishing material thereover is minimized.
- These and other features and characteristics of the present invention will be apparent from the following detailed description in which reference is made to the enclosed drawings which illustrate a preferred embodiment of the present invention.
-
- Figure 1 is an enlarged cross-sectional elevation in perspective of a protective skin employed in the heat insulating panel in accordance with the present invention, with the protective skin having a thin layer of reflecting material applied to the outer surface thereof.
- Figure 2 is an enlarged cross-sectional elevation in perspective of a heating insulating panel employing the protective skin shown in Figure 1 to define one surface thereof in accordance with the present invention.
- Figure 3 is a cross-sectional elevation illustrating the heat insulating panel in accordance with the present invention supported on a roof supporting structure and having roofing material applied thereover to form a composite built-up roofing structure.
- Referring now to the drawings wherein like reference characters represent like elements, there is shown in Figure 1 a
protective skin 12 used in forming a compositeheat insulating panel 10 in accordance with the present invention. Theprotective skin 12 preferably comprises a single faced corrugated paper board structure having a corrugatedpaper board medium 14 and anouter liner 16 adhered to the crest portions of the corrugated medium with a suitable adhesive, such as for example a wet strength adhesive. A thin layer of reflectingmaterial 20, which may for example comprise a thin sheet of aluminum foil, is in turn adhesively secured to the outer surface of theliner 16, i.e., the surface opposite to the surface adhered to the crest portions of thecorrugated medium 14. The compositeprotective skin 12 may be provided with a plurality of pre-perforations 22 which pass through thecorrugated medium 14, thepaper board liner 16 and the thin layer of reflectingmaterial 20, for a purpose to be explained more fully hereinbelow. - There is shown in Figure 2 a
heat insulating panel 10 in accordance with the present invention which is particularly useful as a roofing panel for construction of a built-up roof. Thepanel 10 comprises upper and lowerprotective skins 12, 13 having acore 24 of foam material therebetween such as for example phenolic foam material which is dimensionally moisture sensitive. The upperprotective skin 12 comprises a skin such as shown in Figure 1 having a thin layer of reflectingmaterial 20 thereon, whereas the lower protective skin 13 is of a similar construction to theupper skin 12 with the exception that no layer of reflecting material need be provided. Thus, it will be noted in Figure 2 that the thin layer of reflectingmaterial 20 need only be provided on one of the outer surfaces of the formed heat insulatingroofing panel 10, i.e., on the surface of the corrugated paper board facing away from thecorrugated medium 14 and also away from thecore 24 of the phenolic foam material therebetween. - The upper and lower
protective skins 12, 13 both preferably comprise single faced corrugated skins which provide for a good adhesion betweenskins 12, 13 and thephenolic foam material 24 therebetween as a result of the reduction of the amount of volatile materials accumulated between theskins 12, 13 during the manufacturing process and of the foamable resin compound passing through the plurality of pre-perforations 22 provided therein. This feature is more fully disclosed in U.S. Patent 4227356, which is hereby incorporated by reference, and which discloses that a good bond strength between thefoam core 24 and the corrugatedprotective skins 12, 13 is provided. - Also, as more fully discussed in the aforementioned Patent 4227356, the heat insulating board or
panel 10 may be provided with a plurality of post-perforations 26 which provide for an increased bond between thecore 24 of the foam, theprotective skins 12, 13 and theroof supporting structure 30 on one side of the heat insulatingroofing panel 10 and the finishing roofing membrane 32 on the other side thereof by means of theroofing adhesive 34 and theroofing bitumen 26 which penetrates through the post- perforation holes during the process of forming the resulting roofing structure 40 (see Figure 3). In this regard, the roofing material (either the roofing adhesive 34 for securing thepanels 10 to theroof supporting structure 30 or thebitumen 36 applied over the upper surface of theroofing panels 10 during the construction of the roof 40) will seep through the post-perforations 26 and formplugs 28 which provide a firm water resistant bond between the roofing materials and the heat insulating roofing panel orboard 10. - More particularly, during the construction of a built-
up roof 40, a plurality of the heat insulatingroofing panels 10 such as shown in Figure 2 are placed on a suitableroof supporting structure 30, which may for example comprise a corrugated sheet steel support, the crests or peaks of which serve to support theroofing panels 10. This is shown in cross-section in Figure 3. In this placement of theroofing panels 10 on thecorrugated support structure 30, thepanels 10 are arranged in side by side relationship to cover the entire upper surface of thecorrugated support structure 30. Each of thepanels 10 is arranged so that the thin layer of reflectingmaterial 20 provided on the outer surface of one of the sides of thepanels 10 faces away from theroof supporting structure 30, i.e., to face upwardly as shown in Figure 3. Thus, it will be appreciated that thethin layer 20 of reflecting material will be exposed to any sun radiation which is present during this phase of the construction of the roof. - Each of the
roofing panels 10 may be suitably secured to the corrugatedroof supporting structure 30 with anysuitable adhesive 34, such as for example by roofing adhesive which may penetrate the bottom protective skin 13 through the post-perforations 26. This will form theaforementioned plugs 28 in the lower side of thepanel 10. After thepanels 10 have been laid up on theroof supporting structure 30 with thelayers 20 of reflecting material facing the sun, one or more layers of roofing material are then applied over the upper surfaces of theheat insulating panels 10. These roofing materials may comprise bituminous roofing materials such as alternating layers ofasphalt 36, and asphaltsaturated roofing felts 38, with the system then being gravelled over to complete the finishedroof structure 40. In the embodiment shown in Figure 3, four layers each ofasphalt - As noted in the Background of the Invention section, prior art heat insulating roofing panels constructed of foam material have experienced problems in curling or warpage. This is believed in part to be due to the fact that the foam material has a tendency to absorb and retain moisture. For example, the foam materials may have a tendency to absorb approximately 10% moisture by weight when in an environment at 50% relative humidity at room temperature. During the construction process in the prior art in which the panels are initially placed on the roof support, and exposed and unprotected from the sun radiation, the heat from the sun radiation on the upper surface of the panels can cause a high temperature differential across the opposite surfaces which can have the effect of driving the moisture in the foam material away from the hot side towards the cold side, and/or uneven evaporation of the moisture therewithin. For example, up to a 55°F differential (140°F at the upper surface and 95°F at the lower surface) has been experienced with the prior art heat insulating roofing panels. The high temperature differential across the prior art panels (i.e., panels in which no reflecting material is provided on the outer surface of the panel) is thus believed to have caused the curling or warpage of the panels. For example, curling of up to one inch in a two inch thick roofing panel has been experienced.
- However, in accordance with the present invention in which the
roofing panels 10 are provided with athin layer 20 of reflecting material on the outer upper surface thereof, the effects of curling are greatly reduced. It is believed that this is the result of the fact that thethin layer 20 of reflecting material serves to reflect and direct the sun radiation away from the upper surface of theheating panel 10 before the application of theroofing material panels 10. Thus, in accordance with the preferred embodiment of the present invention in which a 20 of aluminum foil is adhesively secured to the outer upper surface of theroofing panel 10, the thickness being below .001 inches, for ex- , ample on the order of .00035 inches, the amount of curling experienced in a two inchthick roofing panel 10 has been reduced to below 3/8 inch and in most instances to 1/4 inch or less. - It should be appreciated that although the present invention has been mainly described with reference to heat insulating panels for built-up roofs, the principles employed could also be used for heat insulating panels for building constructions in general. For example, insulated foam sheathing panels nailed or secured to the outside side walls of buildings, which have also experienced some problems of curling in the past, could be provided with a thin layer of reflecting material on the outer surface to minimize curling or warpage of the panels prior to the application of shingles or siding thereover.
- Preferably, the
layer 20 of reflecting material is adhered to theliner 16 ofcorrugated paper board 12 or other material utilized as the protective skin of theroofing panel 10 by means of a high wet strength adhesive. In this regard, by wet strength adhesive it should be understood that any adhesive which maintains the bond between theliner 16 and thelayer 20 of reflecting material over a long period of time of water immersion, can be employed. For example, such suitable wet strength adhesive may comprise thermosetting polyvinyl acetate based adhesive as well as neoprene adhesives. The same types of adhesive may also be utilized in adhesively securing theliner 16 to thecorrugated medium 14. - Further, the
thin layer 20 of reflecting material, in accordance with the present invention, is preferably adhesively secured to thecorrugated paper board 12 or other medium prior to the use of thepaper board medium 12 in the manufacturing of theheating panels 10. In other words, thethin layer 20 of reflecting material is preferably initially laminated to thecorrugated paper board 12 in the preferred embodiment to form aprotective skin 12 prior to the manufacture of theheating panel 10 and the use of theprotective skin 12 in such manufacturing process. In this regard, desirably the manufacture of thepanels 10 will be in accordance with a continuous method similar to that described for example in U.S. Patent No. 3,821,337 to Bunclark, issued January 28, 1974, which reference is herebyincorpor- ated by reference in its entirety. For example, twenty- four inch wide panels can be manufactured which are then cut into four foot lengths. In this regard, U.S. Patent No. 3,821,337 not only describes a continuous process for the manufacture of heat insulating panels but also describes resins which may be employed therein. - However, it should also be appreciated that the present invention could be employed with other types of foam materials which are dimensionally thermo - or hydro - sensitive, such as for example some poly-styrene or urethane foams, in order to minimize curling or warping of the heat insulating panels.
- The density of the resulting
core 24 of open celled phenolic foam material is generally in the range of about 1.5 to 6.0 lb./ft3 and preferably about 2 to 3.5 lb./ft3. The preparation of the resin and its foaming are well known in the chemical art as well as the roofing art and needs no further elaboration herein. Examples of such materials can be found in U.S. Patent Nos. 3,741,920, 3,726,708, 3,694,387, 3,779,956, 3,877,967, and 3,953,645. - Although various types of media may be used for the
protective skins 12, 13 (or for providing a corrugated protective skin), it is preferred that single faced corrugated paper board be used, since such material is generally less costly in comparison to other suitable materials. Such suitable single faced corrugated paper board may for example include a liner and medium of kraft, semi-chemical or other similar paper material. Typical weights for such paper board may range from about 26 lb./l000 ft 2 to about 42 lb./1000 ft ; however, it should be understood that other weights for the paper board could be utilized. - Also, although in accordance with the preferred embodiment of the present invention both
pre-perforations 22 andpost-perforations 26 are provided in theprotective skins 12, 13, (in accordance with the principles of the aforementioned Patent 4,227,356), it will be appreciated that use ofsuch perforations protective skins 12, 13 could be used in combination with athin layer 20 of highly reflective material adhesively secured to the outer surface thereof. - While in accordance with the preferred embodiment, the layer of reflecting material preferably comprises a
thin layer 20 of aluminum foil, it should also be appreciated that other types of highly reflective materials could also be utilized which would serve to reflect and direct sun radiation away from the upper surface of the panel when same is supported on a building structure. Such highly reflective material should preferably have an emissivity of less than 0.30, and more preferably less than 0.10. Aluminum foil has an emissivity of approximately 0.05. Another suitable material may for example comprise a very thin layer of gold. Furthermore, although in the preferred embodiment the layer of aluminum has a thickness of less than 0.001 inches and preferably on the order of .00035 inches, other thicknesses may of course be used. Themain consideration in this regard may be the cost of such materials. Thus, it will be appreciated that the thinner thelayer 20, the less expensive the cost for the resultingpanel 10. The major requirement on the thickness of the highly reflective material is whether the material may be adhesively secured to the protective skin medium. - While the preferred embodiment of the present invention has been shown and described, it will be understood that such is merely illustrative and that changes may be made without departing from the scope of the invention as claimed.
Claims (17)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US14363080A | 1980-04-25 | 1980-04-25 | |
US143630 | 1980-04-25 |
Publications (2)
Publication Number | Publication Date |
---|---|
EP0039158A2 true EP0039158A2 (en) | 1981-11-04 |
EP0039158A3 EP0039158A3 (en) | 1982-02-03 |
Family
ID=22504900
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP81301563A Withdrawn EP0039158A3 (en) | 1980-04-25 | 1981-04-09 | Insulating foam building panel and method of construction utilizing such panels |
Country Status (4)
Country | Link |
---|---|
EP (1) | EP0039158A3 (en) |
CA (1) | CA1146331A (en) |
DK (1) | DK152392C (en) |
NO (1) | NO811393L (en) |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2166688A (en) * | 1984-11-13 | 1986-05-14 | Robert Douglas Hawkins | Resin-bonded laminates |
GB2205873A (en) * | 1987-06-18 | 1988-12-21 | Coolag Purlboard Ltd | Flat roofing |
GB2271981A (en) * | 1992-10-28 | 1994-05-04 | Flemming Hansen | Support structures/pallets |
AU648973B3 (en) * | 1992-03-19 | 1994-05-05 | Tri-Foam Australia Pty. Ltd. | Insulation for structures |
AU674507B2 (en) * | 1992-03-19 | 1997-01-02 | Tri-Foam Australia Pty. Ltd. | Insulation for structures |
EP2589894B1 (en) * | 2011-11-04 | 2018-07-18 | Berleburger Schaumstoffwerk GmbH | Use of a building protection for installation on a roof waterproofing structure |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4900616A (en) * | 1989-05-31 | 1990-02-13 | Fiberglas Canada, Inc. | Phenolic foam roof insulation of improved dimensional stability |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR2124321A1 (en) * | 1971-02-01 | 1972-09-22 | Upjohn Co | |
US4081939A (en) * | 1976-02-11 | 1978-04-04 | Culpepper & Associates, Inc. | Siding panel backerboard and method of manufacturing same |
Family Cites Families (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CH451488A (en) * | 1966-08-22 | 1968-05-15 | Prignitz Hapri Leichtbau | Method and device for the production of building panels |
US3874983A (en) * | 1973-12-17 | 1975-04-01 | Dow Chemical Co | Laminate construction |
DK142377B (en) * | 1975-04-14 | 1980-10-20 | Karl Aage Pederson | Method and form for making a building element with a foamed plastic core and a metal plate consisting of a surface coating. |
US4227356A (en) * | 1978-03-23 | 1980-10-14 | Exxon Research & Engineering Co. | Composite foam roof insulation |
-
1981
- 1981-03-11 CA CA000372793A patent/CA1146331A/en not_active Expired
- 1981-04-09 EP EP81301563A patent/EP0039158A3/en not_active Withdrawn
- 1981-04-22 DK DK180181A patent/DK152392C/en active
- 1981-04-24 NO NO811393A patent/NO811393L/en unknown
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR2124321A1 (en) * | 1971-02-01 | 1972-09-22 | Upjohn Co | |
US4081939A (en) * | 1976-02-11 | 1978-04-04 | Culpepper & Associates, Inc. | Siding panel backerboard and method of manufacturing same |
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2166688A (en) * | 1984-11-13 | 1986-05-14 | Robert Douglas Hawkins | Resin-bonded laminates |
GB2205873A (en) * | 1987-06-18 | 1988-12-21 | Coolag Purlboard Ltd | Flat roofing |
GB2205873B (en) * | 1987-06-18 | 1991-11-27 | Coolag Purlboard Ltd | Flat roofing |
AU648973B3 (en) * | 1992-03-19 | 1994-05-05 | Tri-Foam Australia Pty. Ltd. | Insulation for structures |
AU674507B2 (en) * | 1992-03-19 | 1997-01-02 | Tri-Foam Australia Pty. Ltd. | Insulation for structures |
GB2271981A (en) * | 1992-10-28 | 1994-05-04 | Flemming Hansen | Support structures/pallets |
GB2271981B (en) * | 1992-10-28 | 1996-08-07 | Flemming Hansen | Composite Pallet and Methods of Making It |
EP2589894B1 (en) * | 2011-11-04 | 2018-07-18 | Berleburger Schaumstoffwerk GmbH | Use of a building protection for installation on a roof waterproofing structure |
Also Published As
Publication number | Publication date |
---|---|
EP0039158A3 (en) | 1982-02-03 |
DK152392B (en) | 1988-02-22 |
NO811393L (en) | 1981-10-26 |
DK152392C (en) | 1988-07-18 |
DK180181A (en) | 1981-10-26 |
CA1146331A (en) | 1983-05-17 |
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