JP2022536123A - 建築パネル、アセンブリ及び関連付けられた方法 - Google Patents
建築パネル、アセンブリ及び関連付けられた方法 Download PDFInfo
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- JP2022536123A JP2022536123A JP2021572615A JP2021572615A JP2022536123A JP 2022536123 A JP2022536123 A JP 2022536123A JP 2021572615 A JP2021572615 A JP 2021572615A JP 2021572615 A JP2021572615 A JP 2021572615A JP 2022536123 A JP2022536123 A JP 2022536123A
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- panel
- scrim
- roofing panel
- roofing
- filamentous
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Abstract
Description
本出願は、2019年6月7日に出願された米国仮出願第62/858,450号及び2019年8月23日に出願された米国特許仮出願第62/890,981号の優先権の利益を主張するものであり、これらの開示は参照により本明細書に組み込まれる。
一般に、本開示によるパネルは、業界で既知の任意の好適な構造又は構成を含んでもよい。例えば、パネルは、パネルコアの有意な構成要素として(例えば、最大85重量パーセント以上の量で)石膏を含有するパネルであってもよく、又はパネルコアの構成要素として他の構成要素と組み合わせて(例えば、85パーセント未満の量で)石膏を含有するパネルであってもよい。パネルコア内に存在し得る他の構成要素の例としては、セメント系材料、酸化マグネシウム、飛灰、繊維ガラス、セルロース、又は他の繊維が挙げられるが、これらに限定されない。更に、本開示は、一般に、石膏コア又は層を含む建築パネル(本明細書では「構造パネル」とも呼ばれる)に関するが、他のパネルは、本明細書に記載される建築構造用に好適な木質系、発泡系、及び他の材料系パネルなど、石膏パネルに好適に代用されてもよい。すなわち、本開示の様々な実施形態は、石膏パネルを参照して説明又は例示されているが、石膏コア及び他のパネル特徴は、これらの他のパネル又は構造材料の種類の好適な構成要素と交換され得ることを理解されたい。具体的には、このようなパネル及び他の材料は、参照により本明細書に組み込まれる文献に記載されている。例えば、これらのパネル及びマットは、本明細書に記載されるように、任意の好適なフェーサ材料又は他の外部コーティング材料と共に、任意の好適なパネルコア(例えば、パネルの構造コアを形成する1つ以上の層)を含んでもよい。
特定の実施形態では、図10~図14及び図17~図18に示されるように、パネルは、屋根デッキパネルであってもよい。例えば、建物の構造における屋根デッキアセンブリ又はシステムの設置は、一般に、建物の屋根を支持するためのフレームを構築することと、屋根デッキシステムの他の構成要素を支持するための表面を提供するために、フレーム波形シートに固着させることと、波形シート平面支持部材に固着させることと、平面支持部材に、良好な耐候性を有する外部仕上げ材料に固着させることと、を伴う。上述の波形シートと平面支持部材との間に挟まれた断熱パネルを含む屋根デッキシステムも広く使用されている。このようなシステムは、特性及び耐候性において断熱性であるように設計される。このような屋根デッキシステムは、加熱に使用されるエネルギーを節約し、空調に使用されるエネルギーを節約するために使用され得る。
本明細書に記載される構造パネルを製造する方法も提供される。本方法は、(i)糸状スクリムを不織マットフェーサと関連付けることと、(ii)パネルの表面を形成するために弾性/可撓性表面コーティングを塗布することと、(iii)比較的高いパネルコア密度を有するパネルコアを形成することと、のうちの1つを含み、風揚圧力、耐水性、釘引き、曲げ、及び透過性などのパネルの他の物理的特性を保持しながら、高い耐衝撃性を含む、高められた耐降雹性を提供してもよい。具体的には、これらの方法は、Moderate Hail(クラス1-MH)、Severe Hail(クラス1-SH)、及び/又はVery Severe Hail(クラス1-VSH)に関するFM 4470耐降雹性クラスの規格を満たす、本明細書に開示される構造パネルをもたらしてもよい。
実験試験を実施して、FM 4470規格による様々な構造パネルの耐降雹性特性を査定した。FMクラス1-VSH試験の場合、2インチ(51mm)直径の氷球は、53~58ft-lb(72~79J)の衝撃エネルギーを達成するために、圧縮空気を使用して、組み立てられた屋根試験サンプルにおいて、152~160f/秒(46~49m/秒)の速度で推進される。クラス1-VSH格付けを達成するための許容基準は、屋根カバー、現場継ぎ目、及び屋根カバーの下の基質上での亀裂又は分裂又は分離又は破裂の兆候を示さないことである。基質中の小表面押込みは、衝撃点で許容される。
本明細書に開示されるような不織マットフェーサと関連付けられた糸状スクリムを有する石膏パネルを製造し、以下の実施例に従って風揚圧力性能について試験した。製品及び試験材料の風揚圧力試験は、実験室ベースの比較であり、したがって製品性能は、認定された屋根試験機関での試験に対して変化し得る。
Claims (81)
- 屋根葺きパネルであって、
固化石膏コアと、
前記固化石膏コアと関連付けられた糸状スクリムであって、前記糸状スクリムが複数の開口部を間に画定する細長い糸で構成されたメッシュを含む、糸状スクリムと、
前記糸状スクリムと関連付けられた不織マットフェーサと、
を備える屋根葺きパネル。 - 前記糸状スクリムが少なくとも約4oz/yd2の重量を有する、請求項1に記載の屋根葺きパネル。
- 前記糸状スクリムが約4oz/yd2~約25oz/yd2の重量を有する、請求項1に記載の屋根葺きパネル。
- 前記細長い糸が繊維ガラス糸である、請求項1に記載の屋根葺きパネル。
- 前記細長い糸の各々が複数の細長いフィラメントを含む、請求項1に記載の屋根葺きパネル。
- 各細長い糸中の前記複数の細長いフィラメントが一緒に接着されている、請求項5に記載の屋根葺きパネル。
- 各細長い糸中の前記複数の細長いフィラメントが尿素ホルムアルデヒド又はアクリル系バインダと一緒に接着されている、請求項6に記載の屋根葺きパネル。
- 前記細長い糸の各々が約0.05インチ~約0.5インチの幅又は直径を有する、請求項1に記載の屋根葺きパネル。
- 前記複数の開口部の各々が約0.01in2~約0.5in2の面積を有する、請求項1に記載の屋根葺きパネル。
- 前記糸状スクリムがフィラメントの双方向性、三方向性、又は四方向性パターンを有する、請求項1に記載の屋根葺きパネル。
- 前記メッシュが互いに離間した2セットのほぼ平行な細長い糸を含み、前記2セットが互いにほぼ垂直に配設されている、請求項1に記載の屋根葺きパネル。
- 各セット内の前記ほぼ平行な細長い糸が約0.1インチ~約0.5インチの距離で互いに離間している、請求項11に記載の屋根葺きパネル。
- 前記2セットのほぼ平行な細長い糸が一緒に接着されている、請求項11に記載の屋根葺きパネル。
- 前記2セットのほぼ平行な細長い糸が尿素ホルムアルデヒド又はアクリル系バインダと一緒に接着されている、請求項13に記載の屋根葺きパネル。
- ほぼ平行な細長い糸の各セットが前記屋根葺きパネルの少なくとも1つの縁部にほぼ平行に配設されている、請求項11に記載の屋根葺きパネル。
- ほぼ平行な細長い糸の各セットが前記屋根葺きパネルの少なくとも1つの縁部に対して約45度の角度で配設されている、請求項11に記載の屋根葺きパネル。
- 前記不織マットフェーサが複数のガラス繊維で形成された不織繊維ガラスマットを含む、請求項1に記載の屋根葺きパネル。
- 不織繊維ガラスマットフェーサが前記マットの100平方フィート当たり約1.5ポンド~約4.0ポンドの坪量を有する、請求項17に記載の屋根葺きパネル。
- 前記複数のガラス繊維の各々が約1~約17ミクロンの平均直径、及び約1/16インチ~約1インチの平均長さを有する、請求項17に記載の屋根葺きパネル。
- 前記不織繊維ガラスマットが結合されて、尿素ホルムアルデヒド又はアクリル系バインダを有する一体型マット構造を形成する、請求項17に記載の屋根葺きパネル。
- 前記石膏コアの反対側の前記不織マットフェーサの表面上に弾性コーティングを更に備える請求項1に記載の屋根葺きパネル。
- 前記弾性コーティングが、エラストマーアクリル共重合体/樹脂、ポリビニルブチラール、ポリ尿素/ポリウレタンハイブリッド、ポリウレタンエラストマー、合成ゴム、及びゴム加工/エラストマーコーティング材料の少なくとも1つを含む、請求項21に記載の屋根葺きパネル。
- 前記弾性コーティングが約1ミル~約30ミルの厚さを有する、請求項21に記載の屋根葺きパネル。
- 前記弾性コーティングが少なくとも約50%の伸びを示す、請求項21に記載の屋根葺きパネル。
- 前記弾性コーティングが少なくとも200psiの引張強度を示す、請求項21に記載の屋根葺きパネル。
- 前記弾性コーティングが少なくとも約50psiの引裂強度を示す、請求項21に記載の屋根葺きパネル。
- 前記弾性コーティングが約18A~約72Aのショア硬度格付けを有する、請求項21に記載の屋根葺きパネル。
- 前記弾性コーティングが約10lb/msf~約165lb/msfの重量で存在する、請求項21に記載の屋根葺きパネル。
- 前記不織マットフェーサが、前記屋根葺きパネルの対向側を形成し、前記対向側が、前記屋根葺きパネルの裏側と反対側であり、前記裏側が、設置時に前記屋根葺きパネルが設置される建物の内部に面するように構成されており、
前記弾性コーティングが、前記屋根葺きパネルの対向側上にある、
請求項21に記載の屋根葺きパネル。 - 前記固化石膏コアが少なくとも2つの石膏層を含み、前記少なくとも2つの石膏層のうちの少なくとも1つが、他の少なくとも2つの石膏層のうちの少なくとも1つよりも高い湿潤密度を有するスレートコート層である、請求項1に記載の屋根葺きパネル。
- 前記石膏コア又はその大部分の層が約45lb/ft3~約80lb/ft3の密度を有する、請求項1に記載の屋根葺きパネル。
- 前記固化石膏コア又はその大部分の層が、(i)約5lb/msf~約15lb/msfの量のシロキサン、又は(ii)約1lb/msf~約10lb/msfの量のシリコネート、又はその両方を含有する、請求項1に記載の屋根葺きパネル。
- 前記屋根葺きパネルが約1/4インチ~約1インチの厚さを有する、請求項1に記載の屋根葺きパネル。
- 前記屋根葺きパネルが、減圧下で8つ以下の締結具を有する屋根葺きアセンブリ上で試験された1/4インチパネルに対して、少なくとも120lb/ft2の耐風揚圧力性を示す、請求項1に記載の屋根葺きパネル。
- 前記屋根葺きパネルが、減圧下で8つ以下の締結具を有する屋根葺きアセンブリ上で試験された5/8インチパネルに対して、少なくとも195lb/ft2の耐風揚圧力性を示す、請求項1に記載の屋根葺きパネル。
- 前記屋根葺きパネルが、糸状スクリムを有しない同一の屋根葺きアセンブリ内に設置されている他の同一のパネルよりも高い耐風揚圧力性を示す、請求項1に記載の屋根葺きパネル。
- 前記屋根葺きパネルは、前記屋根葺きパネルが、より少ない締結具を有する他の同一の屋根葺きアセンブリに設置されるときに、糸状スクリムを有しない他の同一のパネルに少なくとも同一の耐風揚圧力性を示す、請求項1に記載の屋根葺きパネル。
- 前記屋根葺きパネルが、クラス-1 FM 4470 VSH(Very Severe Hail)規格を満たす、請求項1に記載の屋根葺きパネル。
- 建築パネルであって、
固化石膏コアと、
前記固化石膏コアと関連付けられた2つの糸状スクリムであって、各糸状スクリムが複数の開口部を間に画定する細長い糸で構成されたメッシュを含む、2つの糸状スクリムと、
前記固化石膏コアの対向面に配設された2つの不織マットフェーサであって、各不織マットフェーサが、糸状スクリムと関連付けられている、2つの不織マットフェーサと、
を備える建築パネル。 - 各糸状スクリムが約4oz/yd2~約25oz/yd2の重量を有する、請求項39に記載の建築パネル。
- 前記細長い糸の各々が複数の細長い繊維ガラスフィラメントを含む、請求項39に記載の建築パネル。
- 各不織マットフェーサが複数のガラス繊維で形成された不織繊維ガラスマットを含む、請求項39に記載の建築パネル。
- 屋根葺きパネルを製造する方法であって、
糸状スクリムを不織マットフェーサと関連付けることであって、前記糸状スクリムが複数の開口部を間に画定する細長い糸で構成されたメッシュを含む、関連付けることと、
前記糸状スクリム及び不織マットフェーサを石膏スラリーと関連付けることと、
前記石膏スラリーが、固化石膏コアの少なくとも一部分を形成するように固化することを可能にすることと、
を含む方法。 - 前記糸状スクリムを前記不織マットフェーサと関連付けることが、前記糸状スクリム及び前記不織マットフェーサを前記石膏スラリーと関連付けることと同時に起こる、請求項43に記載の方法。
- 前記糸状スクリムを前記不織マットフェーサと関連付けることが、前記糸状スクリム及び前記不織マットフェーサを前記石膏スラリーと関連付けることの前に起こる、請求項43に記載の方法。
- 前記糸状スクリムが少なくとも約4oz/yd2の重量を有する、請求項43に記載の方法。
- 前記糸状スクリムが約4oz/yd2~約25oz/yd2の重量を有する、請求項43に記載の方法。
- 前記細長い糸が繊維ガラス糸である、請求項43に記載の方法。
- 前記細長い糸の各々が複数の細長いフィラメントを含む、請求項43に記載の方法。
- 各細長い繊維ガラス糸中の前記複数の細長いフィラメントが一緒に接着されている、請求項49に記載の方法。
- 各細長い繊維ガラス糸中の前記複数の細長いフィラメントが尿素ホルムアルデヒド又はアクリル系バインダと一緒に接着されている、請求項50に記載の方法。
- 前記細長い糸の各々が約0.05インチ~約0.5インチの幅又は直径を有する、請求項43に記載の方法。
- 前記複数の開口部の各々が約0.01in2~約0.5in2の面積を有する、請求項43に記載の方法。
- 前記糸状スクリムがフィラメントの双方向性、三方向性、又は四方向性パターンを有する、請求項43に記載の方法。
- 前記メッシュが互いに離間した2セットのほぼ平行な細長い糸を含み、前記2セットが互いにほぼ垂直に配設されている、請求項43に記載の方法。
- 各セット内の前記ほぼ平行な細長い糸が約0.1インチ~約0.5インチの距離で互いに離間している、請求項55に記載の方法。
- 前記2セットのほぼ平行な細長い糸が一緒に接着されている、請求項55に記載の方法。
- 前記2セットのほぼ平行な細長い糸が尿素ホルムアルデヒド又はアクリル系バインダと一緒に接着されている、請求項57に記載の方法。
- ほぼ平行な細長い糸の各セットが前記屋根葺きパネルの少なくとも1つの縁部にほぼ平行に配設されている、請求項55に記載の方法。
- ほぼ平行な細長い糸の各セットが前記屋根葺きパネルの少なくとも1つの縁部に対して約45度の角度で配設されている、請求項55に記載の方法。
- 前記不織マットフェーサが複数のガラス繊維で形成された不織繊維ガラスマットを含む、請求項43に記載の方法。
- 前記不織繊維ガラスマットフェーサが前記マットの100平方フィート当たり約1.5ポンド~約4.0ポンドの坪量を有する、請求項61に記載の方法。
- 前記複数のガラス繊維の各々が約1~約17ミクロンの平均直径、及び約1/16インチ~約1インチの平均長さを有する、請求項61に記載の方法。
- 前記不織繊維ガラスマットが結合されて、尿素ホルムアルデヒド又はアクリル系バインダを有する一体型マット構造を形成する、請求項61に記載の方法。
- 前記石膏コアの反対側の前記不織マットフェーサの表面に弾性コーティングを塗布することを更に含む、請求項43に記載の方法。
- 前記弾性コーティングが塗布され、周囲条件で固化される、請求項65に記載の方法。
- 前記弾性コーティングが、エラストマーアクリル共重合体/樹脂、ポリビニルブチラール、ポリ尿素/ポリウレタンハイブリッド、ポリウレタンエラストマー、合成ゴム、及びゴム加工/エラストマーコーティング材料の少なくとも1つを含む、請求項65に記載の方法。
- 前記弾性コーティングが約1ミル~約30ミルの厚さを有する、請求項65に記載の方法。
- 前記弾性コーティングが少なくとも約50%の伸びを示す、請求項65に記載の方法。
- 前記弾性コーティングが少なくとも200psiの引張強度を示す、請求項65に記載の方法。
- 前記弾性コーティングが少なくとも約50psiの引裂強度を示す、請求項65に記載の方法。
- 前記弾性コーティングが約18A~約72Aのショア硬度格付けを有する、請求項65に記載の方法。
- 前記弾性コーティングが約10lb/msf~約165lb/msfの重量で存在する、請求項65に記載の方法。
- 前記糸状スクリム及び前記不織マットフェーサを前記石膏スラリーと関連付けることが、少なくとも1つの石膏スラリーを前記糸状スクリム上に堆積させることを含む、請求項43に記載の方法。
- 前記糸状スクリム及び前記不織マットフェーサを前記石膏スラリーと関連付けることが、少なくとも2つの石膏スラリーを前記糸状スクリム上に堆積させることを含み、前記少なくとも2つの石膏スラリーのうちの少なくとも1つが、他の少なくとも2つの石膏スラリーのうちの少なくとも1つよりも高い湿潤密度を有するスレートコートスラリーである、請求項74に記載の方法。
- 前記石膏コア又はその大部分の層が約45lb/ft3~約80lb/ft3の密度を有する、請求項43に記載の方法。
- 前記石膏スラリーが、(i)約5lb/msf~約15lb/msfの量のシロキサン、又は(ii)約1lb/msf~約10lb/msfの量のシリコネート、又はその両方を含有する、請求項43に記載の方法。
- 前記屋根葺きパネルが約1/4インチ~約1インチの厚さを有する、請求項43に記載の方法。
- 前記屋根葺きパネルが、減圧下で8つ以下の締結具を有する屋根葺きアセンブリ上で試験された1/4インチパネルに対して、少なくとも120lb/ft2の耐風揚圧力性を示す、請求項43に記載の方法。
- 前記屋根葺きパネルが、減圧下で8つ以下の締結具を有する屋根葺きアセンブリ上で試験された5/8インチパネルに対して、少なくとも195lb/ft2の耐風揚圧力性を示す、請求項43に記載の方法。
- 前記屋根葺きパネルが、クラス-1 FM 4470 VSH(Very Severe Hail)規格を満たす、請求項43に記載の方法。
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US62/890,981 | 2019-08-23 | ||
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WO2024084348A1 (en) * | 2022-10-20 | 2024-04-25 | Georgia-Pacific Gypsum Llc | Lightweight gypsum board |
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