U.S. patent number 3,899,855 [Application Number 05/364,089] was granted by the patent office on 1975-08-19 for peaked roof structure of polyurethane molded building panels with integral, bonded, low-density urethane insulation backing.
This patent grant is currently assigned to Nathaniel G. Kanrich. Invention is credited to William Gadsby.
United States Patent |
3,899,855 |
Gadsby |
August 19, 1975 |
Peaked roof structure of polyurethane molded building panels with
integral, bonded, low-density urethane insulation backing
Abstract
A molded building panel which is durable, fire-retardant,
weather resistant and which provides an insulating inner core has a
variegated skin resembling a hand-split shake, shingle or other
surface with a density of from 25 to 60 pounds per cubic foot and
an integral, insulating, low-density, foam core of a density
ranging from 4 to 12 pounds per cubic foot. The skin surface of the
panels is sealed with an elastomeric, ultra-violet, stabilized
polymer incorporating minor amounts of a fire retardant. The panels
are designed to be interlocked with one another in conjunction with
sealing means to seal them against leakage. Each of the panels has
cast-in-place clips for securing the panels to rafters of a roof or
to studding in the event of its use as exterior siding for a
building.
Inventors: |
Gadsby; William (Seattle,
WA) |
Assignee: |
Kanrich; Nathaniel G. (Seattle,
WA)
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Family
ID: |
26919695 |
Appl.
No.: |
05/364,089 |
Filed: |
May 25, 1973 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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225548 |
Feb 11, 1972 |
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Current U.S.
Class: |
52/90.1; D25/139;
52/309.9; 52/314; 52/515; 52/520; 52/525; 52/539; 52/544; 52/555;
264/45.1; 264/46.6 |
Current CPC
Class: |
E04D
1/2956 (20190801); E04D 3/355 (20130101); E04D
3/361 (20130101); E04D 3/351 (20130101); E04D
3/365 (20130101); E04D 1/2918 (20190801); E04D
3/32 (20130101); E04D 3/38 (20130101); E04D
1/265 (20130101) |
Current International
Class: |
E04D
3/24 (20060101); E04D 3/00 (20060101); E04D
3/32 (20060101); E04D 3/35 (20060101); E04D
1/26 (20060101); E04D 1/00 (20060101); E04D
3/36 (20060101); E04D 3/38 (20060101); E04D
3/365 (20060101); E04b 007/02 () |
Field of
Search: |
;52/309,536,554,538,555,539,314,541,520,515,523-525,543,544,546,549
;264/46 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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2,019,319 |
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Nov 1971 |
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DT |
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1,433,266 |
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Feb 1966 |
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FR |
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Primary Examiner: Abbott; Frank L.
Assistant Examiner: Braun; Leslie A.
Attorney, Agent or Firm: Seed, Berry, Vernon &
Baynham
Parent Case Text
BACKGROUND OF THE INVENTION
This application is a continuation-in-part of Ser. No. 225,548,
filed Feb. 11, 1972, now abandoned.
Claims
The embodiments of the invention in which an exclusive property or
privilege is claimed are defined as follows:
1. A roof structure comprising:
spaced rafters extending from the peak of the roof,
rows of side-by-side, prefabricated, durable, fire-retardant
building panels bridging the gaps between the rafters and secured
thereto, each roof panel comprising a unitary, variable-density,
closed-cell, polyurethane foam panel having an outer, variegated
skin surface resembling a hand-split shake roof of natural wood
with a density from 25 to 60 pounds per cubic foot and an inner,
integral, insulating, low-density, polyurethane foam with a density
ranging 4 to 12 pounds per cubic foot, an ultra-violet stabilized
sealant coating over the exterior surface of each panel, a
continuous recessed portion along the lower edge of each panel
extending the entire length of the lower edge for mating and keying
with the upper edge of an abutting roof panel,
means for securing the panels to the rafters, such means including
(1) clips cast into each of the upper corners of each panel, each
clip provided with an inwardly extending slot and tab portion
extending beyond the terminating upper edge of the panel through
which means are driven into the rafter to secure the panel to the
rafter, and (2) clips cast into each of the lower corners of the
panel within the recessed portion, each clip having a tab extending
outwardly into the recessed portion mating with the slot of the
clips in the upper edges of an abutting panel, and
a sealant between the abutting edges of each panel.
2. A durable, fire-retardant, insulating building panel having a
surface simulating a natural building material and comprising:
a planar, unitary, variable-density, closed-cell, polyurethane foam
panel having an outer variegated skin of one-eighth inch to 2
inches thick resembling a natural building material with a density
of from 25 to 60 pounds per cubic foot, an inner, integral,
insulating, polyurethane foam layer with a density of from 4 to 12
pounds per cubic foot, and an elastomeric, polyvinyl sealant
coating applied to the outer surface of the high-density foam layer
incorporating an ultra-violet stabilizer and fire-retardant,
a continuous recessed portion along the entire length of the lower
edge of the panel for mating and keying with the upper edge of an
abutting panel,
a first set of clips cast into each of the upper corners of the
panel, each clip provided with an inwardly extending slot and a tab
portion extending beyond the upper edge of the panel through which
means are inserted to secure the panel to a support member, and
a second set of clips cast into each of the lower corners of the
panel within the recessed portion, each of these clips having a tab
portion extending into the recessed portion and mating with the
slot of the first set of clips of an abutting panel.
3. The building panel of claim 1, substantially rectangular shaped,
wherein the outer and inner layers are formed of a polyurethane
made by reacting a polyol having multiple hydroxy groups with an
isocyanate in the presence of a catalyst and a low boiling point,
volatile fluorocarbon blowing agent to form a multibranched, rigid
polyurethane polymer.
4. The building panel of claim 1 wherein the polyurethane
incorporates an inert filler ranging from 2% to 7% by weight.
Description
FIELD OF THE INVENTION
This invention relates to a durable, fire-retardant, fabricated
building panel of variable-density, closed-cell, polyurethane
foam.
PRIOR ART RELATING TO THE DISCLOSURE
The traditional way of fabricating a building has been to construct
a framework, including vertical studs and horizontal plates, attach
a weatherproof barrier to one side thereof and an attractive
surface to the other or interior side thereof. Traditionally,
insulation is placed between the two walls such that the wall forms
a barrier for heat loss as well as keeping wind, rain and other
undesirable elements out of the interior of the structure. Needless
to say, the steps of building the framework, attaching the outer
wall, placing the insulation in place and then attaching the inner
wall consumes a large number of man hours and thus becomes
expensive. Further, if the worker, when placing the insulation in
place, is not careful he will leave gaps which will tend to
decrease the value of the insulation.
Various structural methods have been introduced which cut down the
number of man hours required to build a structure. These approaches
have included the use of 4 .times. 8 sheets of plywood or
alternatively using prefabricated walls including all of the
elements of a unit size and constructing with the building block
concept. All of the structures, however, have still required the
insertion of insulation between the studs as a separate step either
on the building site or during the fabrication of the wall. Whereas
the concept of backing a wall surface with an insulative product is
known to be old, as taught by the U.S. Pat. No. 3,362,119 granted
to Murphery, U.S. Pat. No. 3,025,198 granted to Dunn, and the
concept of having an insulated panel likewise is old as illustrated
by U.S. Pat. No. 3,258,841 to Butcher. Butcher fabricates an entire
wall structure including studs and plates with an insulation
material foamed in place thus interlocking the various elements
such as the studs to each other as well as to one of the wall
surfaces.
Other patents, such as U.S. Pat. No. 3,619,343, disclose a plastic
roof product of open-cell, expanded polyolefins having a sealant
placed on the exposed surface of the expanded sheeting. Moog, U.S.
Pat. No. 3,410,044, describes a foamed, plastic-based construction
brick having a low-density, foamed core and high-density, smooth
skin. Belgian Pat. No. 640,453 describes interlocking roofing
panels having a hard plastic outer surface and a foamed core.
The primary objects of this invention are to provide fabricated
building panels for use as roofing or exterior siding of a building
of a particular variable-density, closed-cell, polyurethane foam
wherein the outer surfaces of the panels are coated with an
elastomeric sealant providing adequate durability against
weathering. Other objects of this invention are to provide building
panels incorporating cast-in-place clips for securing the panels to
studs or rafters for interlocking the panels together. Other
objects of this invention are to provide a building panel having a
tough, high-density, polyurethane foam outer surface and an
integral interior insulating core of low-density, polyurethane
foam; to provide a building panel which can be easily and quickly
applied having an exterior configuration simulating hand-split
shakes, shingles, clapboard or other particular surface; to provide
unitary, prefabricated, durable building panel wherein the exterior
surface may be colored to any desired color and which is sealed
against damage by weathering; to provide a building panel wherein
the expansion and contraction characteristics caused by heat and/or
cold will not cause physical separation of the panels relative to
one another; and to provide a prefabricated building panel
including a mechanically interlocked high-density polyurethane foam
outer skin and a low-density, polyurethane foam inner core which do
not separate during thermal stress.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a building panel having an exterior
skin configuration resembling a hand-split shake roof and which
embodies the principal features of the present invention;
FIG. 2 is a horizontal cross-section through the panel of FIG.
1;
FIG. 3 is a vertical cross-sectional view of two adjacent panels of
the type illustrated by FIG. 1 showing the manner of securing the
panels to a structural building element such as a rafter or stud
and the configuration of the clips cast into the panels;
FIG. 4 is a plan view of the abutting panels of FIG. 3; and
FIG. 5 illustrates the preferred method of securing panels
resembling a hand-split shake roof or rafter spaced on 16 inch
centers.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a building panel is illustrated having an
exterior configuration resembling that of hand-split cedar shakes
for roofing or exterior siding. The building panel of this
invention may have any configuration, such as clapboard, or may be
made to simulate other natural materials. As shown in FIG. 1, the
panel 1 has an exterior surface 2 including horizontal lap lines 3
and vertical separation lines 4, such that the appearance is that
of siding or roofing made of individual, hand-split cedar shakes
placed in horizontal rows.
Referring to FIG. 2, the panel is fabricated in a mold having an
inner surface configured with the design which the finished panel
is to assume. The panel has a high-density, polyurethane foam outer
surface 5 having a density ranging from 25 to 60 pounds per cubic
foot and an inner, low-density polyurethane foam core 6 having
density ranging from 4 to 12 pounds per cubic foot. The inner core
provides insulating qualities to the building panel and is
mechanically interlocked with the high-density skin of the panel so
that the high-density and low-density portions are not subject to
separation by thermal or other such stresses. Fabrication of the
building panels illustrated by FIG. 1 is carried out by first
coating the interior surface of the configured portion of a mold
with a parting agent to facilitate removal of the finished product.
Then, a high-density, polyurethane foam having a density ranging
from 25 to 60 pounds per cubic foot, and preferably around 30
pounds per cubic foot, is sprayed into the lower portion of the
mold to a thickness ranging from 1/8 to 2 inches in thickness and
preferably about three-eighths inch. The material used is
preferably a hydroxyl-bearing polyol mixed in equal quantities with
an isocyanate. Either the isocyanate or the polyol may incorporate
an extremely low-boiling fluorocarbon. On mixing of the polyol and
isocyanate, heat is generated which causes the low-boiling
fluorocarbon to volatize, foaming the resulting resin material. The
foamed resin is then sprayed into the mold. Before the high-density
foam layer cures, a low-density, polyurethane inner core of a
density ranging from 4 to 12 pounds per cubic foot is sprayed into
the lower mold on top of the high-density foam. The urethane foam
is preferably the same variety, only utilizing greater amounts of
fluorocarbon gas from an external source to reduce the density of
the resulting product to between 4 and 12 pounds per cubic
foot.
Following introduction of the low-density foam, the mold is closed
with an upper mold portion and the entire panel allowed to cure.
The components preferably used in the preparation of the
polyurethane foam have a cream time of about 60 seconds and a
de-mold time of 10 to 12 minutes, are stable in about 2 hours and
have an ultimate cure time of 24 or more hours. It is preferred to
add a quantity of an inert carrier such as pumice to the polyol
ranging from 2 to 7 wt. %, preferably 5 wt. %. A flexible polyol
may also be admixed with the polyol component making up the
majority of the composition to make the product less brittle on
removal from the mold.
Following curing, the panel is removed from the mold and the
exterior surface of the mold is sprayed with a sealant which is
ultra-violet stabilized and which incorporates inert fillers
rendering the coating substantially fire-retardant. A preferable
protective coating is an elastomeric, polyvinyl pre-polymer
manufactured and sold under the tradename DECADEX from Liquid
Plastics of Preston, Great Britain.
The building panel may be colored by (1) introduction of a pigment
into the high-density foam which forms the outer surface of the
panel with concurrent use of a clear sealant or by (2) use of a
naturally colored, high-density foam layer over which is added a
pigmented sealant.
It is desirable that the building panel have inert materials added
to it to achieve greater fire-retardant qualities even though the
polyurethane foam has, in and of itself, signifiant fire-retardant
qualities.
The building panels are generally manufactured in sizes for
securing to rafters or studs spaced on 16 or 24 inch centers.
Generally, the sheets are made in the following sizes: 32 inches
.times. 48 inches, 48 inches .times. 48 inches and 48 inches
.times. 96 inches.
FIG. 3 shows a vertical cross-section of two abutting panels. The
lower edge of each panel is provided with a recessed portion 7
having an upper wall 8 meeting with a back wall 9. The back wall is
provided with an indented portion 10. The recessed portion 7
extends the full length of the lower edge of the building panel.
Clips 11, of metal or other suitable material, are cast in place
during the molding process in the respective lower corners of each
of the building panels, as illustrated by FIG. 4. The clip 11
includes a projecting tab portion 12 which projects beyond the back
wall 9 of the recessed portion 7.
The upper edge of each of the building panels includes a rear wall
13 having an integral projection 14 which mates with the indented
portion 10 in the back wall of the recessed portion of an adjacent
building panel to interlock or key the building panels together.
Clips 15 are cast in the upper corners of each of the building
panels as illustrated by FIG. 4, each clip having a lower tab
portion 16 which projects beyond the plane of the back wall 13 a
sufficient distance for a nail, staple or other means to be driven
through the tab portion to secure the panel to a rafter or a stud
17. Spaced above the tab portion is a base member 18 of the clip to
which are secured integral legs 19 and 20 which secure the clip in
the cast building panel. A slot 21 between the base 18 and the tab
16, which mates with the tab portion 12 of the adjacent panel, is
provided. Referring to FIG. 5, showing installation of building
panels resembling a hand-split shake roof, the panels are generally
started at the gutter line. The tab portions 12 of clips 11 along
the lower marginal edge of each panel are bent down and secured by
staples or nails through the tab of the rafter. The tabs 16 at the
top edge of each building panel are secured to the rafters by
staples or nails through the tab portion into the rafter.
Additional panels are installed in side-by-side relation to the
initially installed panel with a sealant spread along the side
edges of the abutting panels to seal them together. A preferable
sealant is an epoxy polysulfide sealant manufactured by A.D.C.O. of
Michigan Center, Michigan which is sufficiently elastomeric to
allow expansion and contraction of the building panels without loss
of sealing. When one row of panels is completed, a second row of
panels is installed, with the lower edges of the second row of
panels interlocking with the upper edges of the lower row of
panels, as illustrated by FIG. 3. A sealant 23 is used between the
abutting panels. Preferably, the rows of panels are staggered
relative to one another as illustrated by FIG. 5 in order to
eliminate a series of straight line joints.
When hips and valleys are part of the roof system, the sheets may
be cut along a diagonal by a saw and adjacent sheets fitted
together using an adhesive sealant between the adjoining surfaces.
It is preferable to use a valley underlayment of polyethylene or
polyvinylchloride film of sufficient thickness.
The following examples are included as exemplary of the invention
but are not to be considered limiting in any manner.
EXAMPLE I
A polyurethane pre-polymer sold under the tradename POLYLITE 841 by
Reichold Chemical Company, incorporating about 5% pumice on a
weight basis and 5% of a flexible polyol sold by Wyandotte
Industries, was mixed in equal weight ratios with an isocyanate
catalyst sold under the tradename POLYLITE 745 by Reichold Chemical
Company. The polyurethane pre-polymer incorporated a low-volatile
fluorocarbon blowing agent. The urethane mixture was sprayed into
the inner part of a mold having an inner surface configuration
resembling that of hand-split shakes to a thickness of about
three-eighths inch and a density of about 30 pounds per square
foot. Before the high-density urethane skin cured, additional
fluorocarbon blowing agent was injected into the mixture of
urethane pre-polymer and catalyst in an amount sufficient to yield
a foamed product having a density of about 12 pounds per cubic
foot. This low-density foam was sprayed into the mold over the
high-density skin and the mold closed with an upper mold portion.
The foamed product in the mold was allowed to cure for about 24
hours. The building panel was removed from the mold and a
protective sealant coating of an elastomeric, polyvinyl prepolymer
incorporating asbestos powder and stabilized against ultra-violet
radiation was coated over the exterior surface of the panel. The
preferred sealant is one sold under the tradename DECADEX by Liquid
Plastics of Preston, Great Britain.
EXAMPLE II
A building panel was made in the same manner as described with
respect to Example I, only using a polyol (Part A of B-12-60) of
Polymir, Inc. of San Leandro, California, mixed in equal quantities
with an isocyanate catalyst (Part B of B-12-60). The polyol
pre-polymer in this instance included a quantity of a volatile
fluorocarbon blowing agent which, when mixed with the isocyanate
and pre-polymer, volatized to give a foamed product ranging in
density from 25 to 60 pounds per cubic foot.
* * * * *