WO2017086917A1 - Sous-couche avec isolation thermique - Google Patents

Sous-couche avec isolation thermique Download PDF

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Publication number
WO2017086917A1
WO2017086917A1 PCT/US2015/060915 US2015060915W WO2017086917A1 WO 2017086917 A1 WO2017086917 A1 WO 2017086917A1 US 2015060915 W US2015060915 W US 2015060915W WO 2017086917 A1 WO2017086917 A1 WO 2017086917A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
underlayment
emittance
core material
reinforcement
Prior art date
Application number
PCT/US2015/060915
Other languages
English (en)
Inventor
Cory L. Groft
Thomas W. Dauber
Thomas E. WRIGHT
Original Assignee
Environmentally Safe Products, Inc.
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 Environmentally Safe Products, Inc. filed Critical Environmentally Safe Products, Inc.
Priority to PCT/US2015/060915 priority Critical patent/WO2017086917A1/fr
Priority to CR20180329A priority patent/CR20180329A/es
Priority to CA3005706A priority patent/CA3005706C/fr
Publication of WO2017086917A1 publication Critical patent/WO2017086917A1/fr

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Classifications

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    • B32B15/00—Layered products comprising a layer of metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
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Definitions

  • the present disclosure relates generally to roofing materials, and more specifically to an improved underlayment satisfying underlayment and thermal insulation functions.
  • underlayments are typically strips of material that are attached to the roof deck and overlapped to create a downward drainage plane.
  • the underlayment provides a secondary moisture barrier for the roof deck, in addition to the outer roof covering.
  • R-value which is the thermal resistance to heat flow.
  • a larger R-value means that the material or system has greater thermal resistance and more insulating ability as compared to a smaller R-value.
  • Such R- values can be added together. For instance, for homogeneous assemblies, the total R-value of an insulation assembly is the sum of the R-value of each layer of the assembly. These layers may include sheathing and finishes, the insulation itself, air films, and weatherproofmg elements.
  • the Low-E product is an effective thermal insulation addition to a metal, tile, or composite shingle roof covering.
  • the application of such products offer the first R-value or values to address the heat before it would enter the attic space.
  • reflective insulations such as Low-E Insulation greatly reduce the heat transfer across a roofing system, which allows for lower BTU gain or loss, which in turn equates to energy savings for the consumer.
  • Such a reflective layer product has been used in roof applications for some time, but requires the additional cost and labor associated into combining it with an approved roof underlayment product.
  • the thermal performance aspect is well-received.
  • a reflective product must be installed with an International Code Council (ICC)-approved roofing underlayment.
  • ICC International Code Council
  • This dual-product approach equates to extra material cost in addition to more than twice the labor cost, since the extra reflective product must be installed in addition to the conventional underlayment.
  • the performance/investment return for an energy upgrade is the cost-cycle payback.
  • energy upgrades should be performed for existing or new structures for energy-conservation purposes, applying this balanced approach of the cost-cycle payback allows consumers to make a more-informed decision when investing in the energy performance of their homes. For this reason, all insulation products and/or systems are weighed for this measurement, as well as for specific thermal performance.
  • the underlayment includes a core material and an upper emittance layer having an exterior surface.
  • An upper reinforcement layer is positioned between the upper emittance layer and the core material.
  • a first encapsulation layer is positioned between the upper emittance layer and the upper reinforcement layer.
  • a second encapsulation layer is positioned between the upper reinforcement layer and the core material.
  • the underlayment includes a lower emittance layer having an exterior surface and a lower reinforcement layer between the lower emittance layer and the core material.
  • a third encapsulation layer is positioned between the lower emittance layer and the lower reinforcement layer.
  • a fourth encapsulation layer is positioned between the lower reinforcement layer and the core material.
  • the roofing assembly includes a roof deck having a flat surface area and a plurality of underlayments overlapping each other on the flat surface area.
  • Each of the underlayments include a core material, an upper emittance layer having an exterior surface, and an upper reinforcement layer between the upper emittance layer and the core material.
  • a first encapsulation layer is positioned between the upper emittance layer and the upper reinforcement layer.
  • a second encapsulation layer is positioned between the upper reinforcement layer and the core material.
  • Each of the underlayments includes a lower emittance layer having an exterior surface and a lower reinforcement layer between the lower emittance layer and the core material.
  • a third encapsulation layer is positioned between the lower emittance layer and the lower reinforcement layer.
  • a fourth encapsulation layer is positioned between the lower reinforcement layer and the core material.
  • Another example is a method of manufacturing an underlayment with thermal insulation.
  • An upper foil laminate including an upper emittance layer having an exterior surface, an upper reinforcement layer, a first encapsulation layer between the upper emittance layer and the upper reinforcement layer and a second encapsulation layer on the upper reinforcement layer opposite the first encapsulation layer is assembled.
  • a lower foil laminate including a lower emittance layer having an exterior surface, a lower reinforcement layer, a third encapsulation layer between the lower emittance layer and the lower reinforcement layer and a fourth encapsulation layer on the lower reinforcement layer opposite the third encapsulation layer is assembled.
  • the upper foil laminate is placed over a core material.
  • the lower foil laminate is placed under the core material.
  • the upper foil laminate, core material and lower foil laminate are laminated together to form the underlayment.
  • FIG. 1 shows the application of an improved underlayment sheet providing thermal insulation on a roof assembly
  • FIG. 2 is a cross-section view of the improved underlayment sheet shown in FIG. i;
  • FIG. 3 is an exploded view of the layers of the improved underlayment sheet in FIG. 1;
  • FIG. 4 is a table of R- and U-values for the improved underlayment sheet in FIG. 1 for various roof systems.
  • FIG. 1 is a perspective view of a roofing assembly 100 that includes an underlayment 110 that is attached to a roof deck 102 before the application of a roof covering (not shown) such as shingles.
  • the underlayment 110 in this example is an approved roofing underlayment as defined by ICC AC 188 while providing thermal insulation performance to the roofing assembly 100.
  • the roofing assembly 100 includes the roof deck 102 having a flat surface 104 defined by outer edges or eaves.
  • the roof deck 102 covers the underlying building and supports the roof covering that will serve as the exterior to the roof assembly 100.
  • the underlayment 110 in this example is shaped as a rectangular strip having a width of 4 feet, a 4 inch flange, and a length of 125 feet.
  • the thicknesses of the underlayment 110 may range from approximately 1/8 inch and 7/32 inch in this example.
  • the flange of the underlayment 110 in this example overlaps laterally in an area 120 with two other underlayments 112 and 114.
  • a vertical overlap 122 is applied on the side surface of the underlayments 112 and 114.
  • the underlayments 110, 112, and 114 are applied to the roof deck 102 in overlapping fashion to cover the entire flat surface 104.
  • FIG. 2 is a cross-section of the underlayment 110 and FIG. 3 is an exploded view of the components of the underlayment 110 in FIG. 1.
  • the underlayment 110 includes a non- permeable core material 200.
  • the core material 200 is a closed-cell polyethylene foam, but other core materials such as polyolefm foam or bubble packaging materials could be used.
  • the material 200 has a thickness of 1/8" (0.125 mil) or 7/32" (0.2187 mil). Other ranges of thicknesses may range from 1/16" (0.0625 mil) to 1 ⁇ 2" (0.5 mil) for the core material 200.
  • the core material 200 serves the underlayment function as a moisture barrier.
  • An upper non-permeable encapsulation layer 202 and a lower non-permeable encapsulation layer 204 are located on the top and the bottom of the non-permeable core material 200.
  • the encapsulation layers 202 and 204 are composed of .0005 mil thick polyethylene heat seal.
  • Alternative materials for the encapsulation layers 202 and 204 include other members of the polyolefm family such as polypropylene, polyester, etc.
  • the encapsulation layers 202 and 204 may vary between +50% and -10% in thickness and, therefore, may be between .001 and .0002 mils in thickness.
  • An upper reinforcement material layer 206 is joined to the surface of upper non- permeable encapsulation layer 202 opposite the core layer 200.
  • a lower reinforcement material layer 208 is joined to the surface of the lower non-permeable encapsulation layer 204 opposite the core layer 200.
  • the upper reinforcement material 206 is a 2x2 fiberglass scrim material. Scrim is a term known in the art to refer to crossed lines of plastics or other appropriate material that serve to strengthen the overall product and to prevent stretching damage to the layers.
  • the 2x2 references 2 yarns vertically and 2 yarns of scrim horizontally per every square inch of surface area.
  • cross-woven scrim, polyester, polyethylene, or polypropylene materials constructed in various patterns such as 5x5, tri-D, Diamond, and 8x8 may be used for the upper reinforcement material 206.
  • the lower reinforcement material 208 is a 5x5 fiberglass scrim.
  • cross- woven scrim, polyester, polyethylene, or polypropylene materials constructed in various patterns such as 2x2, tri-D, Diamond, and 8x8 may be used.
  • the combination of the 2x2 scrim on the upper reinforcement material 206 and the 5x5 scrim on the lower reinforcement material 208 achieves the tensile strength required for finished product.
  • the scrim material for the reinforcement layers 206 and 208 provides the underlayment 110 with a tensile strength of approximately 42.8 pounds per inch width in a machine direction and 39.9 pounds per inch width in a cross-machine direction on a test specimen where the test specimen has a size of approximately 1" wide by 6" long.
  • Another upper encapsulation layer 210 is joined to the opposite surface of the upper layer reinforcement material 206.
  • Another lower encapsulation layer 212 is joined to the opposite surface of the lower layer reinforcement material 208.
  • the encapsulation layers 210 and 212 are composed of .0005 mil thick polyethylene heat seal.
  • the encapsulation layers 210 and 212 may also be between .001 and .00002 in thickness.
  • the top and bottom surfaces of the underlayment 110 are composed of a top low- emittance layer 214 and a bottom low-emittance layer 216.
  • the emittance layers 214 and 216 in this example are composed of .0003 mil thick Aluminum.
  • the thickness of the emittance layers 214 and 216 may be +50% to -10% or .0005 mils to .0001 mils.
  • the emittance layers 214 and 216 may be metalized polyester or other low-emittance facing materials.
  • the emittance material may be a reflective material such as approximately 99.4% polished aluminum.
  • the reflective material may be a facing having any suitable amount of emmissivity, for example, greater than about 85%, preferably between about 90%-95% and about 99.9%, even more preferably between about 99.0% and about 99.9%.
  • the underlayment 110 includes the core material 200, an upper emittance layer 214 having an exterior surface and the upper reinforcement layer 206 between the upper emittance layer 214 and the core material 200.
  • the encapsulation layer 210 is positioned between the upper emittance layer 214 and the upper reinforcement layer 206.
  • the encapsulation layer 202 is positioned between the upper reinforcement layer 206 and the core material 200.
  • the underlayment 110 also includes the lower emittance layer 216 having an exterior surface and the lower reinforcement layer 208 between the lower emittance layer 216 and the core material 200.
  • the encapsulation layer 212 is positioned between the lower emittance layer 216 and the lower reinforcement layer 208.
  • the encapsulation layer 204 is positioned between the lower reinforcement layer 208 and the core material 200. In this manner, the reinforcement layers 206 and 208 are encapsulated and do not wick moisture, allowing the underlayment 110 to provide moisture resistance.
  • the deck surface In standard practice, before installing the underlayment 110, the deck surface must be dry and free of dust, dirt, loose nails, and other protrusions. As explained above, the top surface of the underlayment 110 is the emittance layer 214 and is reflective. Thus, the underlayment 110 meets International Building Code (IBC) Chapter 9 and Chapter 15, since a reinforced aluminum foil top surface faces up. In this example, the underlayment 110 is laid horizontally (parallel to the eave of the roof deck 102) with 4-inch (102 mm) horizontal and 6-inch (152 mm) vertical laps as shown in FIG. 1.
  • IBC International Building Code
  • the additional underlayments 112 and 114 are installed in the same manner as the initial underlayment 110 with a 4-inch flange of the upper underlayment, such as the underlayment 112 laid over the lower underlayment such as the underlayment 110.
  • the overlaps run with the flow of water in a shingling fashion.
  • the under layments such as the underlayment 110 are attached to the roof deck 102 with a minimum of No. 12 gage (0.109 inch shank diameter (2.77 mm)) corrosion- resistant steel roofing nails having a minimum 3/8 inch diameter (9.5 mm) heads along with a minimum 1-inch diameter (25.4 mm) plastic caps.
  • No. 16 gage (0.065 inch leg diameter (1.65 mm)) corrosion resistant stapes having minimum 7/6 inch crowns (11.1 mm) may be used.
  • the fasteners must be long enough to penetrate into the sheathing of the roof deck 102 to a minimum of 3 ⁇ 4 inch (19.1 mm) or through the sheathing, whichever is less.
  • the underlayment 110 only has to be preliminarily attached to the roof deck 102 pending attaching of the battens or counterbattens.
  • the minimum roof slope is 2: 12 (17 percent).
  • the underlayment must include two layers and be applied in accordance with IBC Section 1507.2.8 or IBC Section R905.2.7.
  • the underlayment 110 may serve as one of the layers and provide thermal insulation while another layer of the underlayment may conform to either ASTM D2226, Type I; ASTM D4869, Type I; or ASTM D6757, installed in accordance with IBC Section 1507.2.8 or IBC Section R905.2.7.
  • the underlayment must include two layers and be applied in accordance with IBC Section 1507.3.3.1 or IBC Section R905.3.3.1.
  • the underlayment 110 may serve as one of the layers and provide thermal insulation while another layer of the underlayment may conform to either ASTM D2226, Type I; ASTM D4869, Type I; or ASTM D6757, installed in accordance with IBC Section 1507.2.8 or IBC Section R905.2.7.
  • the underlayment must be a minimum of one layer and be applied in shingle fashion.
  • one layer of the underlayment 110 and a layer of an approved roofing underlayment are cemented together with roofing cement complying with ASTM D4586, or one layer of self-adhering polymer-modified bitumen sheet complying with ASTM D1970, or one layer of an ice barrier complying with ICC-ES Acceptance Criteria for Self-adhered Roof Underlayments for Use as Ice Barriers (AC48).
  • the underlayment is applied over the solid substrate in sufficient courses that the underlayment extends from the eave's edge to a point at least 24 inches (610 mm) inside the exterior wall line of the building.
  • the underlayment 110 applied in the field of the roof overlaps the ice barrier.
  • installation of the roof covering may proceed immediately following the underlayment application.
  • the underlayment is covered by a roof covering in accordance with installation procedures.
  • the underlayment 110 may be assembled in three different components.
  • the first two components are an upper foil laminate and a lower foil laminate.
  • the upper foil laminate includes the emittance layer 214, the encapsulation layers 202 and 210, and the upper layer reinforcement layer 206.
  • the lower foil laminate includes the emittance layer 216, the encapsulation layers 204 and 212, and the lower layer reinforcement layer 208.
  • the foam core material 200 is a separate third component.
  • the components are routed on a flame lamination machine to combine the layers in the correct sequence to achieve the finished underlayment 110.
  • the upper and lower foil laminate layers are loosely held together before lamination.
  • the flame laminator fuses all of the components and encapsulates the reinforcement material layers 206 and 208 by applying intense heat and pressure to two nip points while the components are in motion.
  • the upper and lower foil laminates are applied at a rate of approximately 125 lineal feet per minute.
  • the finished underlayment comes out of this process in large master rolls where all layers are infused to one another and the reinforcement layers 206 and 208 are encapsulated by the respective encapsulation layers 202 and 210 and layers 204 and 212.
  • the master rolls are then sent to a rewind station, where they are inspected for any defects and converted into standard size rolls of 500 square feet (4x125) for distribution and application to a roof deck.
  • the underlayment 110 has the unique ability to be considered an approved roofing underlayment as defined by ICC AC 188, while providing thermal performance to a roofing assembly. Encapsulation of the reinforcement material layers 206 and 208 by the encapsulation layers 202 and 210 and 204 and 212, respectively, achieves both thermal performance and insulation. The underlayment 110 allows cooling of roof assemblies with a single layer of covering.
  • FIG. 4 is a table that shows the various R- and U-values for the underlayment 110 having an overall thickness of .125 inch in different roof systems.
  • FIG. 4 also shows the various R- and U-values for an underlayment similar to the underlayment 110 with an overall thickness of .218 inch.
  • the R- and U- values are system values that include measured resistance of the core material 200, and thermal resistance of plane airspaces is applicable.
  • the core R-value is derived by ASTM C518 and the airspace resistance is from the ASHRAE Handbook of fundamentals.
  • the R-value includes an IP R-value that is in imperial units and an SI R-value that is in the international system of scientific units (SI).
  • SI international system of scientific units
  • the U-value is the reciprocal of the respective R-values.
  • FIG. 4 shows the R- and U-values for a roof system having the underlayment in FIG. 2 under shingles with no airspace.
  • the R-value of the underlayment 110 having an overall thickness of .125 inch by itself is .5 (.088 SI) and an underlayment having an overall thickness of .218 inch is 1 (.176 SI).
  • the R-value of the example underlayment 110 may range between .5 and 1.
  • FIG. 4 also shows the R- and U-values for a roof system with different reflective airspaces between 0.5 inch and 3.5 inches using metal or clay tile roofing. The airspaces are created by battens of various thicknesses listed or the raised profile of the finished roof material.
  • the underlayment 110 combines the benefits of reflective insulation technology and standards needed to be considered a roofing underlayment into one product. Strength in both machine- and cross-direction is achieved by the reinforcement layers 206 and 208. The encapsulations layers around the reinforcement layers prevent wicking of moisture that causes delamination when using traditional design practices.
  • the advantages include providing a single underlayment that meets ICC-approved roofing underlayment and thermal insulation combined in one product.
  • the use of a single sheet as opposed to multiple sheets results in reduced material cost and reduced labor costs.
  • the single sheet reduces energy consumption by the thermal insulation. The cost-cycle payback is therefore reduced.
  • the present combined underlayment 110 meets age-cycle testing and, therefore, passes property testing and certification.
  • the underlayment 110 includes encapsulated reinforcement material that isolates the reinforcement material from moisture and wicking. This encapsulation allows the underlayment 110 to serve two functions of an underlayment and thermal insulation with one product.
  • the underlayment 110 meets ICC certification with regard to ICC ES AC 188.
  • the ICC certification allows the underlayment 110 to meet underlayment requirements in ICC, IRC, and other building code books as demonstrated in IRC R905.2.3.
  • the ICC listing of the example underlayment 110 in conformance to the ICC AC 188 standard can be found at (http://www.icc- es.org/Reports/pdf_files/foad_file.cfm

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Building Environments (AREA)
  • Roof Covering Using Slabs Or Stiff Sheets (AREA)
  • Primary Cells (AREA)
  • Cookers (AREA)
  • Electroluminescent Light Sources (AREA)

Abstract

La présente invention concerne une sous-couche qui satisfait à des exigences de sous-couche et présente une isolation thermique. La sous-couche comprend un matériau central et une couche d'émittance supérieure présentant une surface extérieure. Une couche de renfort supérieure est positionnée entre la couche d'émittance supérieure et le matériau central. Une première couche d'encapsulation est placée entre la couche d'émittance supérieure et la couche de renfort supérieure. Une deuxième couche d'encapsulation est placée entre la couche de renfort supérieure et le matériau central. La sous-couche comprend une couche d'émittance inférieure présentant une surface extérieure. Une couche de renfort inférieure est placée entre la couche d'émittance inférieure et le matériau central. Une troisième couche d'encapsulation est placée entre la couche d'émittance inférieure et la couche de renfort inférieure. Une quatrième couche d'encapsulation est placée entre la couche de renfort inférieure et le matériau central.
PCT/US2015/060915 2015-11-16 2015-11-16 Sous-couche avec isolation thermique WO2017086917A1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
PCT/US2015/060915 WO2017086917A1 (fr) 2015-11-16 2015-11-16 Sous-couche avec isolation thermique
CR20180329A CR20180329A (es) 2015-11-16 2015-11-16 Contrapiso con aislamiento térmico
CA3005706A CA3005706C (fr) 2015-11-16 2015-11-16 Sous-couche avec isolation thermique

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3880470A4 (fr) * 2019-09-06 2022-08-10 Wuxi Gissing Auto Acoustic Parts Tech. Co. Ltd. Partie intérieure de véhicule et son procédé de formage par compression de moule chauffé

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2388815A (en) * 2002-09-21 2003-11-26 Don & Low Ltd Improvements in and relating to liquid impermeable and liquid vapour/gas permeable fabrics
US20080022620A1 (en) * 2006-06-26 2008-01-31 Shawn Crowley Flexible weather resistant building wrap
SK50802009U1 (en) * 2009-10-16 2010-04-07 Marie Haasova Reflective thermal vapour-proof insulation
US20110094175A1 (en) * 2007-08-22 2011-04-28 Environmentally Safe Products, Inc. Insulated roof assembly
US20110287216A1 (en) * 2010-05-21 2011-11-24 Groft Cory L Low-e housewrap

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2388815A (en) * 2002-09-21 2003-11-26 Don & Low Ltd Improvements in and relating to liquid impermeable and liquid vapour/gas permeable fabrics
US20080022620A1 (en) * 2006-06-26 2008-01-31 Shawn Crowley Flexible weather resistant building wrap
US20110094175A1 (en) * 2007-08-22 2011-04-28 Environmentally Safe Products, Inc. Insulated roof assembly
SK50802009U1 (en) * 2009-10-16 2010-04-07 Marie Haasova Reflective thermal vapour-proof insulation
US20110287216A1 (en) * 2010-05-21 2011-11-24 Groft Cory L Low-e housewrap

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3880470A4 (fr) * 2019-09-06 2022-08-10 Wuxi Gissing Auto Acoustic Parts Tech. Co. Ltd. Partie intérieure de véhicule et son procédé de formage par compression de moule chauffé

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CA3005706A1 (fr) 2017-05-26
CA3005706C (fr) 2022-12-06
CR20180329A (es) 2019-04-09

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