Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
  • E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights
  • E04D13/16—Insulating devices or arrangements in so far as the roof covering is concerned, e.g. characterised by the material or composition of the roof insulating material or its integration in the roof structure
  • E04D13/1606—Insulation of the roof covering characterised by its integration in the roof structure
  • E04D13/1643—Insulation of the roof covering characterised by its integration in the roof structure the roof structure being formed by load bearing corrugated sheets, e.g. profiled sheet metal roofs
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/10—Inorganic fibres
  • B32B2262/101—Glass fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
  • B32B2264/10—Inorganic particles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2266/00—Composition of foam
  • B32B2266/02—Organic
  • B32B2266/0214—Materials belonging to B32B27/00
  • B32B2266/0278—Polyurethane
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/30—Properties of the layers or laminate having particular thermal properties
  • B32B2307/304—Insulating
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/30—Properties of the layers or laminate having particular thermal properties
  • B32B2307/306—Resistant to heat
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/712—Weather resistant
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2419/00—Buildings or parts thereof
  • B32B2419/06—Roofs, roof membranes

Definitions

• This invention resides in a dramatic improvement in the art of steel deck roof insulation.
• Steel deck roofing is a type of construction widely used in modern buildings, particularly large, industrial buildings.
• Such roofing comprises generally a plurality of longitudinally extending steel beams or cross members, over which are positioned generally planar steel panels, which panels are usually corrugated in order to afford increased strength to the resulting construction.
• This insulation is preferably provided in the form of a plurality of flat, rigid boards, laid side by side on top of the corrugated steel panels.
• insulating boards are then typically covered with a waterproof surface, in order to seal the boards and the steel deck roof from moisture.
• a waterproof surface In order to seal the boards and the steel deck roof from moisture.
• the roof consists of three distinct elements; the steel deck roof itself, the insulation board above it, and finally the waterproof surface covering the insulation board.
• Such roofing structures have exhibited adequate thermal insulation and water sealing in operation. However, such roofing structures do not exhibit sufficient heat resisting qualities to pass the standard flame spread tests necessary to allow such products to be used in the construction of steel deck roofing, such as Underwriters' Laboratories construction Class 1 and 2, or Factory Mutual Class 1 construction.
• insulation board produced in this manner is then customarily applied to the roof of a structure to be insulated with the perlite layer facing downwardly, separating the urethane foam layer from the interior of the structure.
• the waterproof covering is then applied to the insulation board construction to seal the materials and thereby complete the roof structure.
• composite insulation board applied to a structure in this manner serves to provide adequate flame spread characteristics to permit it to pass the above mentioned testing procedures, while maintaining adequate insulting characteristics, several disadvantages are exhibited by such construction.
• composite insulation board is customarily applied to a roof with the urethane layer facing upwardly; the perlite layer being positioned between the foam layer and the interior of the structure to reduce heat transfer.
• the facing sheet which is customarily placed over the exposed urethane surface will also be facing upwardly, thereby being exposed to the exterior. This creates additional problems.
• This invention relates to the production of a polymeric insulation board capable of use in conjunction with steel deck roof construction, and in particular to an improved composite roof insulation board having both increased insulating and dimensional characterisitcs, as well as excellent flame spread qualities, and a method for installing such composite insulation boards on the roof of the structure.
• the so produced polyisocyanurate foam is then introduced between two flexible sheet substrates (or facing sheets) , which materials are then passed between two substantially immovable barriers which restrict the expansion of the laminate caused by foaming of the reaction mixture.
• a fiber mat is first disrupted and caused to expand, whereupon it is positioned between the two flexible sheet substrates.
• the polyisocyanurate foam reactants are. then introduced between the two flexible sheet substrates to form the foam board.
• Laminated foam boards produced in this manner exhibit excellent flame spread and dimensional characteristics, and are well suited for use as insulation in steel deck roof construction.
• a layer of perlite insulation material (which is generally shaped to form a board) is positioned between one of the flexible sheet substrates, preferably the substrate which is placed at the bottom of the laminate during its manufacture, and the polyisocyanurate foam layer.
• a perlite layer placed over the polyisocyanurate foam structure will no longer separate at its butting surfaces, as would have occurred if urethane foams had been used in this manner.
• the potential for liquified asphalt to drip through to the building interior is also prevented.
• perlite is a surface well suited to accepting a coating of asphalt to be applied to the roof construction.
• problems of blistering and bubbling which commonly occurred in conjunction with the use of insulation boards of the prior art unexpectedly vanish when the composite insulation boards of the present invention are used.
• the facing sheet of the composite board of the present invention now is applied to the roof facing downwardly, a wider variety of facing materials can be used. In addition to providing an opportunity for cost reduction, the use of hazardous or environmentally questionable materials, such as asbestos, is no longer necessary.
• Figure 1 is a cross sectional view of the composite roof insulation board of the present invention. -
• Figure 2 is a schematic view of an apparatus for producing the composite roof insulation board of the present invention.
• Figure 3 is a cross sectional view of the composite roof insulation board applied to the roof of a structure.
• Foam board 1 generally comprises a polyisocyanurate foam layer 2, a perlite insulation layer 3 attached to a first side 4 of foam layer 2, and facing sheet 5 attached to the second side 6 of foam layer 2.
• Polyisocyanurate foam layer 2 is formed by admixing two components; one component including a polyisocyanate surfactant and a blowing agent; and the other component including a polyol component and an isocyanate trimerization catalyst component.
• one component including a polyisocyanate surfactant and a blowing agent
• the other component including a polyol component and an isocyanate trimerization catalyst component.
• the first group of constituents, the a)components are preferably admixed in a closed vessel.
• the order in which they are added is not particularly critical. This mixing may be done at room temperature.
• the second group of constituents, the b) components actually preferably include a group of six constituents, which are admixed with gentle agitation avoiding the occurrence of turbidity which may be a sign of high acidity.
• This turbidity has been found to be avoidable if the six constituents, including a diol with a molecular weight less than about 150, a polyol with at least three hydroxyls, polyethylene glycol, an amine salt, a metal carboxylate, and a dimethylaminomethyl-substituted phenol, are gradually added in that order, respectively, either in an open or closed vessel, at room temperature.
• fillers or other additives may be used to convey characteristics to the foam board, such as increased dimensional stability, density or flame spread qualities.
• specific examples include inorganic materials such as magnesium silicate, steel powder, aluminum silicate,, borates, zinc oxide, aluminum powder or flakes or glass particles or fibers.
• additives may be added to the a) or b) component or may be sprayed or deposited onto the reaction mixture before foaming takes place.
• Foam layer 2 also preferably includes a mat 7 formed of an inorganic material, preferably a fibergalss mat, e.g. 10 to 50 mils in thickness. Mat 7 is positioned so that the polyisocyanurate foam is caused to foam on either side of and within the mat 7. This provides added strength and flame spread characteristics to the foam layer 2. Details of the preparation and utilization of such a mat 7, may be found in my prior patent applications Serial No. 941,057 filed September 11, 1978 and Serial No. 965,420 filed December 1, 1978. Although foam layer 2 preferably includes such a mat 7, to provide increased strength and flame spread characteristics, it is also possible to produce foam boards 1 without use of such a mat 7 however a decreased strength and flame spread characteristic will be exhibited.
• a mat 7 formed of an inorganic material, preferably a fibergalss mat, e.g. 10 to 50 mils in thickness. Mat 7 is positioned so that the polyisocyanurate foam is caused to foam on either side of and within the mat 7. This provides added strength and flame spread characteristics
• a facing sheet 5 is applied to the side 6 of foam layer 2 opposite to the perlite layer 3, providing a protective covering for the foam layer 2.
• Facing sheet 5 may be any one of a variety of known products. Facing sheet 5 may be inflexible, e.g. drywall, or even another layer of perlite. Facing sheet 5 may also be flexible, e.g. a kraft paper, a polymeric sheet, an asbestos or other inorganic fiber sheet, a polymeric web, a metal foil, a foil-coated, paper a * , resin-impregnated and saturated felt sheet, or a non-woven glass mat which is asphalt-coated or saturated.
• an asbestos paper e.g. a kraft paper
• a polymeric sheet e.g. a polymeric sheet, an asbestos or other inorganic fiber sheet
• a polymeric web e.g. a metal foil, a foil-coated, paper a * , resin-impregnated and saturated felt sheet, or a non
• the facing sheet may be formed of any of the various materials set forth above, and may be the same as, or different from the material used for the facing sheet 5.
• Foam board 1 may be formed by any of a variety of known apparatus.
• foam board 1 may be formed on a double phase laminator 8 provided with two parallel platen conveyer belts 9, 11 and a mixing head 10 attached to a traverse (not shown) and capable of rapid movement along the width of the apparatus 8.
• Each of the platen coveyer belts 9, 11 comprise a series of juxtaposed platens 12, hingedly connected to each other to form a continuous transportation means.
• Platens 12 may be formed of a variety of materials and may vary in size. For example, steel plates having a width on the order of 12 inches have been found satisfactory.
• the ends of conveyer belts 9, 11 are positioned about pairs of opposing, transverse rollers 13, which rollers are adapted to receive the .platens 12 as they traverse the rollers 13, yet which also assure alignment between adjacent platens 12 during their travel between the respective rollers 13.
• the driving gears (not shown) which operate rollers 13, and consequently belts 9, 11, are caused to move in opposite circular directions to convey the materials through the laminator.
• a suitable parallel platen conveyer belt laminator is described in U.S. Patent 4,043,719, although the limiting means to prevent outward escape of foam taught therein is not necessary in the present invention.
• the platen conveyor belts 9, 11 illustrated in Figure 2 are preferably positioned so that the lower surface 14 of the conveyer belt 9, and the upper surface 15 of the conveyor belt 11, are parallel to each other. It will also be noted that conveyer belt 9 is shorter in length than conveyer belt 11. This is preferred, since it is not necessary to position conveyer belt 9 over the composite foam board 1 during the period of time in which the foam layer 2 is forming.
• the input to laminating apparatus 8 is provided with a loading conveyer 16 adapted to receive the perlite boards 3, and a “doctor” or metering roller 17 which is adapted to regulate the amounts of the reactants placed between the facing sheet 5 and the perlite board 3, and consequently, the thickness of the subsequently produced composite foam board 1.
• Loading conveyer 16 comprises a continuous belt 18, the ends of which are positioned about a pair of opposing, transverse rollers 19. Loading conveyer 16 is then operated in known manner to convey a series of perlite boards 3, placed on belt 18, toward the laminating apparatus 8, to form the lower portion of the composites board 1 during formation. These perlite boards 3 are typically on the order of 3 feet in length and 4 feet in width; however these dimensions may readily be varied according to need and machine specifications.
• the perlite boards 3 are then passed between the doctor roller 17 and the base 20 as illustrated. Also passed between these elements are facing sheet 5, and if used, fiber mat 7. In the event an additional facing sheet is applied to the exposed side 6 of the perlite board 3, such a facing sheet would also be suitably applied at this time. During this procedure, the fiber mat 7, which has generally been expanded previously by fiber disruption, will be compressed, however, it will later recover and again expand as the polyisocyanurate begins to foam.
• reaction mixture begins to form the foam, later being restricted in its
• a pressure sensing device (not shown) which furnishes an indication when a predetermined pressure is reached.
• a sensing device or devices may trigger a light whereupon the operator would decrease the amount of reaction mixture deposited per unit area. This may also be done automatically.
• Mixing and deposition of the reaction mixture of components a) and b) may be made by.mixing head 10 attached to a traverse located in front of the doctor roller 17 and caused to move across and above the perlite boards 3 and mat 7.
• the mixing head 10 moves from one side to another, depositing the reaction mixture on the top of the perlite boards 3 as they move into the laminating apparatus 8.
• the traverse may be one such as a Leon traverse and the mixing head may be a model such as a Martin Sweets Model No. 4 sold by Martin Sweets Co. of Louisville, Kentucky, or a mixing head sold by the Admiral Machinery Co. division of Upjohn, Houston, Texas, or Henecke Machinery division of Mobay Chemicals.
• Air may be supplied to the mixing head 10 to deposit a homogenous and consistent reaction mixture and to act as nucleating agent. Further, the mixing head may be provided with an automatic solvent flushing feature whereby the operation can be shut down without clogging the apparatus.
• the constituents of the foam are preferably supplied to the mixing head 10 from separate lines 21. Components a) and b) can therefore advantageously be prepared and stored for extended periods beforehand.
• apparatus 8 may optionally be provided with a dryer 22, adapted to direct heated air onto the surface of the foam layer 2 and facing sheet 5, through a series of outlet ducts 23 for example.
• a finished, cured laminated foam board 1 will then exit from between the platen conveyer belts 9, 11 at 24 having a perlite layer 3 and facing sheet 5 bonded to a foam layer 2, including a mat 7. Since the perlite 3, and the facing sheet 5, adhere perfectly to the foam layer 2, a strong laminated product results.
• edge trimming apparatus 25 forming a regularly shaped product, which may then be cut to any length desired.
• This cutting operation may be performed, for example, using a cross-cut saw 26, positioned as shown, adapted to move transversely to the board whenever a cutting operation is to be performed.
• saw 26 is caused to move in the direction of travel of the laminated foam board 1 during the cutting operation.
• the finished foam board sections may then be stacked at 27 for packaging and shipment.
• Figure 3 illustrates the manner in which composite foam board sections 1 of the type previously described may be applied to the roof 28 of a structure.
• steel sheet sections 29, preferably corrugated for increased strength, are positioned between adjacent steel beams in known manner.
• a coating of asphalt 31 which serves as an adhesive to fixedly connect the composite foam board sections 1 in place.
• the board sections are capable of application to the corrugated sections 29 with the foam layer 2 facing downwardly, and the perlite layer 3 facing upwardly, the facing sheet 5 adhering to the corrugated sections 29 by operation of the ashpalt coating 31.
• the resulting structure may then be coated with asphalt and/or felt paper as desired, in order to provide a waterproof seal capable of being exposed to the weather elements.
• the structure above described, in the orientation specified, is sufficiently heat insulative, heat resistive, and dimensionally stable to pass the testing required to qualify as Class 1 (Factory Mutual testing procedure) roof, thus serving to satisfy the various objects previously set forth.
• Facing sheet 5 may be any one of many known materials. As previously mentioned, the use of asbestos is not required, and consequently, less expensive and less environmentally questionable substances may be used. It is even possible, although less desirable to omit facing sheet 5. Mat 7 may also be formed of any of a variety of materials, although fiberglass is preferred.
• the above described composite board may be formed in a variey of sizes, including a wide variety of thicknesses, lengths and widths.
• Board width is determined primarily by the width of the board forming apparatus 8, as well as the width of the raw materials fed into that apparatus.
• Board length is easily varied by the frequency of the movement of cross-cut saw 26.
• Board thickness may be varied in several ways. Its overall thickness may be varied by altering the spacing between the doctor roller 17 and the base 20, thereby limiting the amounts of reactants passed there between.
• the thickness of the perlite layer 3 may be varied by varying the thickness of the perlite insulation board introduced into the appparatus 8.
• the thickness of the foam layer may also be varied by modifying the relative proportions of a) components to b) components combined at the mixing head 10. In this manner, a wide variety of foam boards 1 may be forming, having R (Resistance) values ranging between 5.65 and 20.0 and C (Conduction) values of 0.17 - 0.05.
• laminating apparatus illustrated in Figure 2 is a restricted-rise type of apparatus
• composite boards 1 of the type described in the present application may also be formed on free-rise types of machinery.
• a variety of board forming devices other than that illustrated in Figure 2 may alternatively be used.
• the perlite layer 3 is illustrated as being placed at the bottom of the composite board during its formation. It is also possible to position to perlite layer 3 along the top of the composite board during its formation, the other elements comprising that board being suitably rearranged to accommodate this.

Landscapes

• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Building Environments (AREA)
• Roof Covering Using Slabs Or Stiff Sheets (AREA)

Applications Claiming Priority (2)

Publications (1)

Family

ID=22317086

Family Applications (1)

Country Status (3)

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Family Cites Families (8)

• 1980
  • 1980-12-23 EP EP81900322A patent/EP0042423A1/de not_active Withdrawn
  • 1980-12-23 WO PCT/US1980/001707 patent/WO1981001816A1/en unknown
• 1981
  • 1981-12-23 GB GB8125667A patent/GB2082968B/en not_active Expired

Non-Patent Citations (1)

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