U.S. patent application number 10/493221 was filed with the patent office on 2005-01-20 for composite water-resistant panels.
Invention is credited to Burns, Ian Lewis, Ponting, Christopher.
Application Number | 20050011155 10/493221 |
Document ID | / |
Family ID | 9909697 |
Filed Date | 2005-01-20 |
United States Patent
Application |
20050011155 |
Kind Code |
A1 |
Ponting, Christopher ; et
al. |
January 20, 2005 |
Composite water-resistant panels
Abstract
A composite panel comprising: a metal decking (1), optionally
pre-coated with a decorative finish on its bottom surface a
profiled metal top sheet (3) provided with a pre-laminated,
waterproof, membranous layer on its top surface, an insulating
layer (2) sandwiched between the top surface of the metal decking
(1) and the bottom surface of the metal top sheet (3) and means (5,
7) for connecting the panel to a frame work (4) and/or another
composite panel to form a substantially water resistant building or
structure.
Inventors: |
Ponting, Christopher;
(Flintshire, GB) ; Burns, Ian Lewis; (Flinstshire,
GB) |
Correspondence
Address: |
BACON & THOMAS, PLLC
625 SLATERS LANE
FOURTH FLOOR
ALEXANDRIA
VA
22314
|
Family ID: |
9909697 |
Appl. No.: |
10/493221 |
Filed: |
May 6, 2004 |
PCT Filed: |
November 7, 2001 |
PCT NO: |
PCT/GB01/04941 |
Current U.S.
Class: |
52/578 ;
52/385 |
Current CPC
Class: |
E04B 7/22 20130101; E04D
3/3606 20130101; E04D 3/352 20130101; E04C 2/292 20130101 |
Class at
Publication: |
052/578 ;
052/385 |
International
Class: |
E04C 003/00 |
Claims
1. A composite panel comprising: a metal decking (1), optionally
pre-coated with a decorative finish on its bottom surface a
profiled metal top sheet (3) provided with a pre-laminated,
waterproof, membranous layer on its top surface, an insulating
layer (21) sandwiched between the top surface of the metal decking
(1) and the bottom surface of the metal top sheet (3) and means (5,
7) for connecting the panel to a framework (4) and/or another
composite panel to form a substantially water resistant building or
structure.
2. A composite panel as claimed in claim 1 characterised in that
the insulating layer comprises one or more of; particle board,
mineral wool and polymeric foams.
3. A composite panel as claimed in claim 1 characterised in that
the insulating layer is chemically bonded to the metal decking
and/or the metal top sheet.
4. A composite panel as claimed in claim 2 characterised in that
the insulating layer comprises polymeric foam injected into a space
between the top surface of the metal decking and the bottom surface
of the metal top sheet.
5. A composite panel as claimed in claim 1 characterised in that
the panel is configured for use in the construction of a flat
roof.
6. A composite panel as claimed in claim 1 characterised in that
the panel is configured for use in the construction of
guttering.
7. A composite panel as claimed in claim 1 wherein the waterproof
membranous material is selected from; styrene butadiene modified
bitumen, atactic polypropylene modified bitumen, polyalphaolefin
modified bitumen, ethylene propylenediene monomer,
chlorosulphonated polyethylene, polyvinyl chloride, copolymer
alloys, polyisobutylene, butadiene acrylonitrile alloys and nitrile
butadiene polymers, ethylene interpolymer, polyepichlorohydrin,
chlorinated polyethylene or neoprene (chloroprene).
8. A method for the manufacture of a composite panel comprising: A.
simultaneously roll-forming a metal sheet and a waterproof,
membranous layer to provide a sheet laminate comprising a metal
layer having a layer of waterproof, membranous material on its top
surface, B. roll-forming a second metal sheet, optionally applying
a decorative coating to the bottom surface of the second metal
sheet; C. arranging the first and second metal sheet with the top
surface of said second sheet opposing the bottom surface of said
first sheet; and D. providing therebetween, a volume of insulating
material.
9. A method as claimed in claim 8 characterised in that steps A and
B are carried out simultaneously.
10. A method as claimed in claim 8 characterised in that step D
involves injecting a foaming polymeric insulating material between
the arranged metal sheets and allowing the composite to cure.
11. A method as claimed in claim 8 characterised in that step D
involves spraying a chemical bonding agent to the top surface of
said decking and the bottom surface of said top sheet and providing
therebetween an insulating material.
12. A method as claimed in claim 8 characterised by the further
step of applying pressure to the composite as it cures.
13. A method as claimed in claim 12 wherein the step of applying
pressure involves the use of a vacuum table, a platen press, a bag
press or a nip rolling apparatus.
Description
[0001] This invention relates to composite panels, including but
not strictly limited to panels for use in the construction of a
flat roof. In particular, the invention relates to a prefabricated
panel which can be conveniently and easily be fitted to a building
or other construction, and a method for manufacture of such a
panel.
[0002] Conventionally, flat roofs are built on site. The usual
methods for manufacture involve the construction of a metal frame
work onto which decking is layed and fixed. A layer of insulation
is then applied and finally a waterproof layer must be added. The
application of the water proof layer, in particular, can be a time
consuming process. Typically this layer may be bonded, eg with hot
asphalt or cold bitumen, or loose laid and ballasted with pebbles
or concrete slabs. Alternatively, they may be mechanically fixed to
the substrate.
[0003] Clearly in poor weather environments it is undesirable and
inconvenient to have to carry out this multi-step process on site.
Accordingly, the present invention aims to provide an article which
can be manufactured in the factory and conveniently and easily
located with a building or structure on-site.
[0004] In accordance with a first aspect the present invention,
there is provided a composite panel comprising;
[0005] a metal decking, optionally pre-coated with a decorative
finish on it's bottom surface a profiled metal top sheet provided
with a pre-laminated, waterproof, membranous layer on it's top
surface,
[0006] an insulating layer sandwiched between the top surface of
the metal decking and the bottom surface of the metal top sheet and
means for connecting the panel to a framework and/or another
composite panel to form a substantially water resistant building or
structure.
[0007] In accordance with a second aspect, the invention provides a
method for the manufacture of a composite panel comprising:
[0008] A. simultaneously roll-forming a metal sheet and a
waterproof, membranous layer to provide a sheet laminate comprising
a metal layer having a layer of waterproof, membranous material on
it's top surface,
[0009] B. roll-forming a second metal sheet, optionally applying a
decorative coating to the bottom surface of the second metal
sheet;
[0010] C. arranging the first and second metal sheet with the top
surface of said second sheet opposing the bottom surface of said
first sheet; and
[0011] D. providing therebetween, a volume of insulating
material.
[0012] Optionally steps A and B may be carried out simultaneously.
Step D may, optionally, be carried out by injecting a foaming
polymeric insulating material between the arranged metal; sheets,
and allowing the composite to cure. Alternatively, step D may
involve spraying a chemical bonding agent to the top surface of
said second sheet and the bottom surface of said first sheet and
providing therebetween an insulating material. Insulating materials
for use in accordance with the method may include, but are not
strictly limited to; particle boards, mineral wool and polymeric
foams. Optionally, to improve bonding between the insulating
material and the two plates, the method my further include a step
where pressure is applied to the composite. The pressure may be
applied by means of, for example, a vacuum table, a platen press, a
bag press or nip rolling while the bonding agent cures. Other means
of improving or accelerating bonding of the plates to the
insulating material will no doubt occur to the skilled
addressee.
[0013] Suitable waterproof, membranous materials for use in
accordance with the invention include vulcanised elastomeric
materials which may be pre-cured, prior to applying the metal sheet
and non-vulcanised elastomeric materials which are applied to the
sheet in uncured form, being capable of curing while in
service.
[0014] Some more specific examples of suitable waterproof
membranous materials include; styrene butadiene modified bitumen,
atactic polypropylene modified bitumen, polyaplphaolefin modified
bitumen, ethylene propylenediene monomer, chlorosulphonated
polyethylene, polyvinyl chloride, copolymer alloys,
polyisobutylene, butadiene acrylonitrile alloys and nitrile
butadiene polymers, ethylene interpolymer, polyepichlorohydrin,
chlorinated polyethylene and neoprene(chloroprene). Suitable
methods for applying these materials to the metal sheet will vary
with the material to be used and will no doubt occur to the skilled
addressee.
[0015] The metal sheeting may be profiled to meet the specific
applications for which the panel is designed, for example, the
bottom sheet may be castellated for use in roofing applications, to
allow air circulation and/or the passing through of utility pipes
and wires. The sides of either or both metal sheets may be suitably
profiled to permit a convenient interlocking fit between sides of
adjacent panels.
[0016] The panels have various applications, particularly where
water impermeability is a desirable feature for a structure. By
suitable adaption of the panels to suitable scales and shapes
and/or the membranous sheet laminate, they may be used in the
efficient assembly of, for example; flat roofing, flashings,
gutters, portable buildings, flooring and walkways, ducting and air
handling, water or silage tanks, oil rigs, swimming pools and pool
ceilings, planters, lining of underground structures, overhead
doors and secret fix roofing.
[0017] For the purposes of exemplification, some embodiments of the
invention will now be further described with reference to the
following Figures, in which;
[0018] FIG. 1 shows a first embodiment of a composite panel of the
invention for use in a flat roofing application;
[0019] FIG. 2 shows a second embodiment of a composite panel of the
invention for use in a flat roofing application;
[0020] FIG. 3 shows a third embodiment of a composite panel of the
invention for use in a flat roofing application;
[0021] As can be seen from FIG. 1, a composite roof panel according
to the invention comprises a profiled metal decking 1 on its lower
surface, a volume of injected polymeric insulating foam 2 filling a
space defined between the profiled metal decking 1 and a metal top
sheet 3 on the upper surface of the composite, the top sheet 3
having thereon a pre-laminated waterproof membranous material. The
panel may mechanically fixed to a metal framework 4 for a roof, by
fasteners 5. A foam thermal break 6 is fitted between adjacent
panels mounted on the framework 4. A flat bracing piece 8 covers
the top of the fasteners 5 is made watertight by heat or solvent
welding waterproof cover strips, 7, along the joins connecting the
bracing piece to the top sheets 3 of adjacent panels.
[0022] FIG. 2 shows a broadly similar arrangement to that of FIG.
1, in this embodiment, the insulating material 2 is provided in the
form of a board of polymeric foam or mineral wood insulation. Also,
the welded waterproof membrane cover strips, 7 are extended to
cover the protruding tops of the fasteners 5.
[0023] FIG. 3 shows a third, alternative embodiment of a roof panel
according to the invention. In this panel, it can be seen the
adjoining sides of two adjacent panels are suitably profiled to
interlock, thereby reducing opportunity for leakage between joins.
As in FIG. 2, a cover strip 7 is extended to cover the top of a
protruding fastener 5. As in FIG. 1, the insulation 2 is provided
in the form of an injected polymeric foam.
[0024] Suitable means for applying waterproof membrane strips as
referred to in this description will vary with the materials used,
but some suitable methods include; seeming with adhesive or solvent
welding, mechanical fastening and hot air welding. It is to be
understood this list is not exhaustive and other suitable means
will not doubt occur to the skilled addressee.
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