Patent Publication Number: US-2013243991-A1

Title: Intermediate composite panel for roofing and walls

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application is a non-provisional application which claims priority on U.S. provisional application No. 61/612,544 filed on Mar. 19, 2012, incorporated herewith by reference. 
    
    
     FIELD OF THE APPLICATION 
     The present application relates to multi-layer construction or building panels and, more particularly, to a intermediate composite panel such as roofing or wall panel and methods of manufacturing and assembling same. 
     BACKGROUND ART 
     In the construction industry, multilayer panels are frequently used, as such panels offer multiple functions related to the layers that compose them. Such multilayer panels can benefit from their various layers (e.g., elastomeric, asphalt, fiberboard, EPS or XPS, fiberglass, mineral wool etc.) to offer features such as structural support, waterproofness, insulation and fire-resistance. 
     In fabricating multilayer panels in factory, in plant, there results faster installation at the construction site, and therefore a reduction on the labor required. Moreover, the quality of assembly of the multilayer panel is controlled in plant, while the assembly of multiple layers on the construction site may result in some errors and incorrect assembly. 
     SUMMARY OF INVENTION 
     It is an aim of the present invention to provide a novel construction panel for walls and/or roofing providing additional features. 
     The panel is a composite product that is made in factory so as to have controlled quality. 
     Therefore, in accordance with the present application, there is provided a composite intermediate panel comprising: a structural layer providing the structural integrity of the composite intermediate panel; pressure-sensitive adhesive layers on opposite main surfaces of the structural panel, the pressure-sensitive adhesive layers applied in plant; a backing sheet layer for each adhesive layer, the backing sheet layer adhered to the pressure-sensitive adhesive layer, and being peelable off the pressure-sensitive adhesive layer to expose the pressure-sensitive layer; and at least one attachment unit of rigid material on at least one of the main surfaces of the building panel, the at least one attachment unit being positioned at a location where mechanical fasteners secure the building panel to a structure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side view, fragmented, of an intermediate composite panel constructed in accordance with an embodiment of the present disclosure; 
         FIG. 2  is a side view, fragmented, of an intermediate composite panel similar to that of  FIG. 1 , with an additional functional layer; 
         FIG. 3  is a side view, fragmented, of an intermediate composite panel similar to that of  FIG. 1 , with rabbet edges; 
         FIG. 4  is a side view of a bottom layer of the intermediate composite panel of  FIG. 1 , as mounted to a structure, with a top layer of composite panel thereon; and 
         FIG. 5  is a top plan view of the intermediate composite panel of  FIGS. 1 and 2 . 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to the drawings, and more particularly to  FIGS. 1 and 5 , an intermediate composite insulated building panel constructed in accordance with an embodiment is generally shown at  10 , and is also referred to as multilayer building panel. 
     In the embodiment of  FIG. 1 , the insulated building panel  10  has five layers, namely a structural layer  12 , adhesive layers  14 , and backing sheet layers  16 . Additionally, attachment units  18  are provided on one of the surfaces of the building panel  10 . 
     The structural layer  12  provides structural integrity to the building panel  10 . More specifically, the structural layer  12  may be a relatively rigid panel made of a polymeric material, such as urethane-based polymers (e.g., polyisocyanurate) or polystyrene, among possibilities. Such material have some structural properties in addition to insulation properties. Moreover, an additive is optionally used to add a flame and/or smoke retardant property to the structural layer  12 . In another embodiment, all six faces of the structural layer  12  are coated with asphalt. As an alternative to the materials suggested above, it is considered to have layer  12  made of a perlite panel, rock wool, wood fibers, expanded or extruded polystyrene, polyurethane, polyisocyanurate, cement, gypsum or other materials. Coatings may be used to treat the structural layer  12  before the application of the adhesive layer  14 , to ensure optimal adherence of the adhesive. The material(s) used for the structural layer  12  are dependent on the contemplated use. For instance, the structural layer  12  may be used for sound insulation, thermal insulation, or the like. 
     The thickness of the structural layer  12  is selected as a function of the contemplated use of the building panel  10  (e.g., flat roof, pitch roof, wall, ceiling, etc.). For instance, a suitable thickness for the structural layer  12  ranges between 0.25″ to 8.0″ (with the thicker range including a functional layer, as described hereinafter). 
     The adhesive layers  14  respectively cover at least a portion of the two main surfaces of the structural layer  12 , if not a substantial portion, or a complete coverage of the main surfaces. It is pointed out that all six surfaces of the structural layer  12  may be covered with adhesive layers  14 . The adhesive for the layer  14  is a pressure-sensitive, auto adhesive applied in plant, whereby the adhesive must maintain adhering properties at ambient temperatures. As an example, the adhesive used for the layer  14  may be at least one of a bitumen adhesive, polyurethane resin, urethane and polyurethane-based adhesive, asphaltic urethane, solvent-based or solvent-free adhesives, acrylic adhesive, chlorinated asphaltic composite, synthetic-polymer adhesives, polyvinyl acetate, polyvinyl alcohol, polyester adhesives, neoprene, butyl rubber, thermoplastic elastomers. 
     The adhesive layers  14  may cover only a portion of the two main surfaces of the structural layer  12 , and be applied in a linear pattern, or as points, among other possibilities. 
     As an example, the adhesive may be applied by a continuous manufacturing process, such that the layers  14  may cover the full surface of the structural layer  12 , or parts of the surface. In an embodiment, between 0.04-0.20 lb/ft 2  of adhesive is applied, although more or less adhesive may be used depending on the conditions in which the building panel  10  will be used. A suitable thickness of adhesive for given conditions ranges between 1/64″ and ⅛″. Again, there may be required more or less adhesive depending on the conditions in which the building panel  10  will be used. By adding the adhesive layer  14  in plant, automated equipment may be used, ensuring that the suitable amount of adhesive is applied, as a lack or an excess of adhesive may affect the performance. For instance, it is considered to use a roll applicator, with induction. The application of adhesive may be followed up by another heating step (e.g., on a conveyor with radiant heating capabilities). Also, the conditions of adhesive application may be controlled in plant, such as temperature, and humidity. The heating steps may be performed to reduce the water content in the adhesive layer  14  in embodiments in which a water-based adhesive is used. 
     It is considered to provide regions (e.g., strips) without adhesive, to ease the manipulation of the panel  10 . For instance, when there is an adhesive layer  14  on both faces of the panel  10 , such regions can be identified to guide the installer in manipulating the panel  10  by these regions. Also, gloves that do not adhere to the adhesive may also be used. The regions can also be used for marking the panel  10 . These regions may be longitudinal strips extending along the full length of the panel  10 , as generally illustrated as A in  FIG. 5   
     The backing sheet layers  16  are installed on the respective adhesive layers  14  also in plant. By installing it quickly after the adhesive layers  14  have been applied (e.g., taking into account a curing time), the backing sheet layer  16  protects the adhesive layer  14  from dust contamination and loss of tackiness. The backing sheet layers  16  are made of material suited for a manual peeling-off action. Therefore, adherence between the adhesive layers  14  and the backing sheet layers  16  is relatively low, while the backing sheet layer  16  has tear-resistance properties. The backing sheet layer  16  may be made of plastic, thermo-fusible plastic, paper, plasticized paper, Kraft paper, organic felt, fiberglass, to fully cover the adhesive layer  14 . 
     In an embodiment, the backing sheet layer  16  is applied above given temperatures to ensure a suitable bond with the adhesive layer  14  (e.g., above 5° C.). An in-plant stabilization period to allow the layers  14  and  16  to bond may also be required. Moreover, a combination of the adhesive layer  14  and backing sheet layer  16  may be applied to a first side of the panel  10 , to then apply layers  14  and  16  to the other side of the panel  10 . 
     The attachment units  18  are preferably positioned onto the adhesive layer  14 , prior to the addition of the backing sheet layer  16 , on one side of the panel  10 . The attachment units  18  therefore remain in position by adhering to the adhesive layer  14 . The backing sheet layer  16  may have marks on its surface to indicate where the attachment units  18  are located, such that the panel  10  may be fixed to the structure by mechanical fasteners without the prior removal of the top backing sheet layer  16 . 
     The attachment units  18  are typically strips of a rigid material (e.g., metals such as galvanized steel, aluminum, stainless steel, or polymeric material). The attachment units  18  may be pre-perforated with holes  19  to receive mechanical fasteners. The attachment units  18  will act as interfaces between mechanical fasteners and the panel  10 , to solidify the interaction between mechanical fasteners and panel  10 . The holes  19  (e.g., pre-perforated) in the attachment strips  18  may be distributed over the full length of the strips  18 , to provide numerous possible fastening locations all along the strip  18 . Therefore, when the panel  10  is connected to uneven surfaces, such as that of a steel deck, the plurality of fastening locations (i.e., holes  19 ) ensure that the fasteners can be aligned parts of the uneven surface (e.g., ridges of the steel deck). In the case of a steel deck, the strips  18  are preferably placed in a transverse or diagonal relation with the ridges of the steel deck. 
     The pre-perforated holes  19  may have any appropriate shape, such as round, obround, rectangular, etc. In a embodiment, the strips  18  do not have any pre-perforated holes. Self-tapping fasteners may be used to secure the panel  10  to a surface or structure, and adequately tap through the strip  18  if there are no pre-perforated holes. An example of measurement of the strip  18  is a width of 1″ for a thickness of 0.07″. The length is as a function of the dimensions of the panel  10 . For instance, the strip  18  may have a length of 18″±2″ for on the 48″ width of the panel. 
     According to an embodiment, the number of attachment units  18  provided on the panel  10  corresponds to the required retention force of mechanical fasteners, taking into account the presence of the adhesive layer  14  contributing to the mechanical bond of the panel  10  to a structure. 
     According to another embodiment, the attachment units  18  are adhered directly to the backing sheet layer  16  or between the adhesive layer  14  and the backing sheet layer  16 , and are therefore exposed from a top surface of the panel  10 . In such a case, mechanical fasteners are firstly used to secure the panel  10  to the structure, and the backing layer sheet  16  is then removed, ripping about the attachment units  18  or the mechanical fasteners to expose the adhesive layer  14 . In this case, an installer will not contaminate the adhesive layer  14  by contacting same. 
     In order to install the panel  10  to a structure, one of the backing sheet layers  16  is manually peeled off from a remainder of the panel  10 , thereby exposing the adhesive layer  14 . The peeling off is preferably performed just before the installation of the panel  10 , to limit the exposure of the adhesive layer  14  to the ambient air at the construction site, and thus limit the loss of tackiness due to solid contaminants present in the air (e.g., dust, dirt). Moreover, the adhesive layer  14  is selected for use at the temperature of the construction site. This way, there is no curing time during which the adhesive of layer  14  is exposed to the contaminants. The panel  10  is pressed against the structure such that the adhesive contacts the structure. Tools such as rollers may be used to ensure a complete contact of the panel  10  with the structure. 
     As shown in  FIG. 4 , mechanical fasteners  20  are then installed to further secure the panel  10  to the structure A. The mechanical fasteners  20  are for instance self-tapping screws, that will purchase into the material of the attachment units  18 , and into the structure A. Moreover, the head of the fastener  20  abuts against the surface of the attachment unit  18 , to apply some pressure onto the attachment unit  18  and keep the panel  10  against the structure A. 
     The second backing sheet layer  16  is then peeled off the upwardly-facing side of the panel, and components (e.g., shingles, roofing panels, membranes, gypsum panel, etc) may be pressed into adhesion with the upper adhesive layer  14  of the panel  10 . 
     In the embodiment of  FIG. 2 , the insulated building panel  10  has six layers, namely the structural layer  12 , the adhesive layers  14 , the backing sheet layers  16 , as well as a functional layer  22  sandwiched between the structural layer  12  and one of the adhesive layers  14 . The functional layer  22  provides additional functions to the building panel  10  described above (e.g., vapor barrier, air barrier, etc). 
     In one embodiment, the building panel  10  is used as a roofing panel, used either for exterior sides of roofs, or interior sides of ceilings. In outdoor applications, the functional layer  22  may form an air/water barrier that is oriented toward the exterior of the building with respect to the layer  12 . The use of the functional layer  22  as air barrier gives the panel  10  the characteristic of resisting to the passage of water (e.g., rain) while being relatively permeable to vapor. The air-barrier functional layer  22  generally prevents outdoor air from infiltrating the building or indoor air from exfiltrating through the envelope made of building panels  10 . Contemplated materials amongst others for the air-barrier functional layer  22  include woven alkenes bound by polypropylene or other polymers, spun polyolefin optionally bound by polymers, sheeted polyethylene. The air barrier is optional if the building panel  10  is used for indoor applications. 
     If the building panel  10  is used as a roofing panel, the functional layer  22  may consist of an elastomeric material which forms the waterproof layer of the building panel  10 , preventing water infiltration through the building panel  10  used as part of the roof. 
     In indoor applications, the functional layer  22  may form a vapor barrier that is oriented toward the interior of the building with respect to the layer  12 . The use of the functional layer  22  as vapor barrier gives the panel  10  the characteristic of being impermeable to the passage of vapor. Accordingly, the functional layer  22  prevents vapor from reaching the structural layer  12  from the interior of the building. Contemplated materials amongst others for the vapor-barrier functional layer  22  include woven polyethylene, woven polypropylene or mixtures thereof, kraft paper with polyethylene, some types of paint or polymers, adhesives and sealants, concrete. The vapor barrier is optional if the building panel  10  is used for indoor applications. 
     In another embodiment, also illustrated by  FIG. 2 , the functional layer  22  is an insulation layer providing the highest thermal value of the layers of the panel  10  and is therefore primarily added for its insulation properties. The insulation layer  22  is preferably selected from expanded polymers. In an embodiment, the insulation layer  22  is expanded polystyrene, molded or cut. Other polymeric materials considered for the insulation layer  22  include non-exclusively expanded and extruded polystyrene, polyisocyanurate (modified polyurethane), as well as expanded resins such as expanded polypropylene, expanded polyethylene, Arcel™, and the like, and mineral fibers and glass fibers. It is considered to use fire-retardant or flame-retardant additives in the insulation layer  22 . 
     The thickness and density of the insulation layer  18  are selected as a function of the desired insulating value required from the building panel  10 . For instance, a suitable thickness for the insulation layer  22  ranges between 0.25″ to 4.0″. 
     The multilayer building panel  10  is assembled in plant/factory. The various layers forming the building panel  10  are bound using suitable adhesives in a laminated fashion. As an example, a polyvinyl adhesive (PVA glue), water-based, asphalt-based or pressure-sensitive adhesives, or hot-melt adhesives may all suitably be used to bond the layers  12  and  22 . 
     Accordingly, the use of the building panel  10  simplifies the construction of walls, ceiling and roofs (e.g., flat roof, pitch roof), in that a composite panel provides simultaneously the features of waterproofness and insulation with stable features since it is assembled in factory in reproducible conditions. Moreover, the presence of the attachment units  18  for use in combination with mechanical fasteners  20  will increase the mechanical strength of the fixation of the panel  10  to the structure A. 
     In order to facilitate the on-site assembly of building panels  10  in side-by-side arrangement to form a roof, a wall or a ceiling, various configurations of the panel  10  are considered. In addition to the flat edges of the panel  10  as illustrated in  FIG. 1 , a few other configurations are illustrated in  FIG. 3 . 
     Referring to  FIG. 3 , the structural layer  12  defines rabbets  30  on two edges of the panel  10 , for complimentary engagement of adjacent composite panels  10 . All four side edges of the panel  10  may be provided with rabbets  30 . 
     In roof applications for the building panel  10 , once the panels  10  form a roof surface by being positioned side by side with mechanical fasteners  20  solidifying the attachment, another layer of panels  10  may be secured onto the first layer, as shown in  FIG. 4 . In such a case, the second layer is simply secured to the first layer by way of the adhesive layers  14 , and thus without mechanical fasteners  20 . Hence, in the embodiment of  FIG. 4 , a top layer of panels  10  is provided. As shown in  FIG. 4 , the top layer of panels  10  is arranged to overlap a joint between the panels  10  of the lower layer. As the top layer of panels  10  positioned atop another layer are not necessarily bound to the roof by mechanical fasteners as mentioned above, the top layer may be without attachment units  18  as shown in  FIG. 4 . 
     When the building panel  10  is used as a wall or ceiling panel, well-suited dimensions are 4′ width by 8′ height or 4′ width by 4′ height, according to standards in the construction industry. Other dimensions are also considered. 
     It is observed that the building panel  10  as described above has sound attenuating qualities. Accordingly, the panel  10  may be used as a wall panel and/or ceiling panel for sound insulation through walls and floors/ceilings (e.g., the panel  10  may be an acoustic floor panel). The embodiments of  FIGS. 1 to 4  allow the panels  10  to provide given functions as described above (e.g., structural force, sound attenuation, insulation, etc), while serving as mechanical link between components. For instance, the panels  10  may be connected on one side to a wooden structure, while supporting on the other side roofing panels, gypsum, etc. 
     The panel  10  intends to ease the installation and to reduce the labour required on construction sites. The intermediate composite panel allows suitable resistance (e.g. wind uplift resistance for roofing applications) with less mechanical fasteners, due to the presence of an adhesive. Moreover, the panel  10  of the present disclosure will cause lower thermal and/or sound conductivity into systems (roofs, walls, ceilings and floors) in comparison to panels requiring more fasteners. Indeed, a larger amount of mechanical fasteners will increase undesired thermal, sound and vapour conductivity into dwellings.