COMPOSITE PANEL

PANNEAU COMPOSITE

English Abstract

A composite panel comprising an in-plant assembly and an elastomer membrane.
Two
or more layers of insulating panels support the elastomer membrane, a first of
the two
layers laminated to the elastomer membrane. An adhesive layer and backing
sheet are
provided, the adhesive layer being on a second of the two layers of insulating
panels.
A method for fabricating a composite panel, comprises in plant: forming at
least a first
layer of insulating material. An elastomer membrane is cut to a size
sufficient to cover
the first layer and extend at least beyond one edge of the first layer. The
cut elastomer
membrane is heated while separate from the first layer. The heated elastomer
membrane is heated onto the first layer.

Claims

CLAIMS:
1. A method for fabricating a composite panel, comprising, in plant:
forming at least a first layer of insulating material;
cutting an elastomer membrane to a size sufficient to cover the first layer
and
extend at least beyond one edge of the first layer;
heating the cut elastomer membrane while separate from the first layer; and
adhering the heated elastomer membrane onto the first layer.
2. The method according to claim 1, wherein adhering the heated elastomer
membrane onto the first layer comprises laminating the heated elastomer
membrane
with a press.
3. The method according to any one of claims 1 and 2, wherein forming a
first
layer comprises forming two layers, one layer being on top of the layer.
4. The method according to claim 3, wherein forming two layers comprises
applying an adhesive on facing surfaces of the two layers.
5. The method according to any one of claims 3 and 4, wherein forming two
layers,
one layer being on top of the layer, comprises offsetting the layers to from a
ship lap
joint on at least two of four edge surfaces.
6. The method according to any one of claims 1 to 5, wherein forming a
first layer
comprises putting at least two subpanels of the insulating material in a side
by side
relation.
7. The method according to any one of claims 1 to 6, further comprising
applying
an adhesive and backing sheet on a surface of the composite panel opposite to
the
surface supporting the elastomer membrane.
8. The method according to any one of claims 1 to 6, further comprising
applying a
vapor-barrier layer on a surface of the composite panel opposite to the
surface
supporting the elastomer membrane.
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9. The method according to claim 8, wherein applying the vapor-barrier
layer
comprises applying the vapor-barrier layer with an auto-adhesive and backing
sheet on
an underside of the vapor-barrier layer.
10. A composite panel resulting from the method of claims 1 to 9, the
composite
panel having at least the first layer of insulating material and the elastomer
membrane.
11. A composite panel comprising:
an in-plant assembly;
an elastomer membrane;
at least two layers of insulating panels, a first of the two layers laminated
to the
elastomer membrane; and
an adhesive layer and backing sheet, the adhesive layer being on a second of
the two layers of insulating panels.
12. The composite panel according to claim 11, wherein the at least two
layers of
insulating material are offset to form ship lap joints on at least two edge
surfaces of the
insulating panels.
13. The composite panel according to any one of claims 11 and 12, wherein
the
elastomer membrane extends beyond at least one edge surface of the insulating
panels.
14. The composite panel according to any one of claims 11 to 13, wherein
the
insulating panels are made of at least one of polyisocyanurate, polystyrene,
stone wool,
fiberboard.
15. The composite panel according to any one of claims 11 to 14, wherein
the
adhesive layer includes a vapor-barrier film.
16. The composite panel according to claim 15, wherein the vapor-barrier
film
membrane extends beyond at least one edge surface of the insulating panels.
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17. The
composite panel according to any one of claims 11 to 16, wherein each
layer of the insulating material are formed of at least two subpanels of the
insulating
material in a side by side relation.
8

Description

CA 02955951 2017-01-23
COMPOSITE PANEL
FIELD OF THE INVENTION
[0001] The present application relates to composite panels of the type used
as a
building material and, more particularly, of the type used as a roofing
insulative panel
with waterproofing and/or vapor barrier characteristics.
BACKGROUND OF THE ART
[0002] Polyisocyanurate is commonly used as an insulating roofing material,
especially for low-slope roofing. One common technique used to create
efficient
isolating systems for roofs is to use at least two thinner superposed layers
of insulating
panels (e.g., polyisocyanurate), as opposed to having one thicker panel.
Hence, it is
common that on-site workers spend a non-negligible amount of time installing
superposed layers of polyisocyanurate panels, in addition to under layers and
over
layers, such as a vapor barrier, and an elastomer membrane.
[0003] Moreover, on the construction site, once such insulating panels have
been
installed, a support panel is then laid on the polyisocyanurate panels to
support a
waterproof elastomer membrane. The support panel is necessary as the elastomer
membrane must be welded onto the roofing structure, often by the use of a blow
torch.
Such welding could damage or burn the insulating layer, whereby the support
panel
forms a protective layer.
[0004] All in all, the construction of low slope roofs may be a costly
procedure, taking
into account the number of steps ¨ installation of a vapor barrier,
overlayering of
polyisocyanurate panels, installation of support panel, welding of elastomer
membrane
¨ these steps performed by construction workers, often at higher wages than
plant
workers. Construction workers may also be exposed to hazardous climate
conditions,
which add another level of complexity to the installation process. Moreover,
as more
steps are performed, there may be an increased risk of faulty installation.
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CA 02955951 2017-01-23
SUMMARY
[0005] It is therefore an aim of the present disclosure to provide a method
of
fabricating composite panels featuring an insulating material such as
polyisocyanurate,
e.g., for roofing applications.
[0006] It is a further aim of the present disclosure to provide a novel
composite panel
featuring an insulating material such as polyisocyanurate, e.g., for roofing
applications.
[0007] Therefore, in accordance with the present disclosure, there is
provided a
method for fabricating a composite panel, comprising, in plant: forming at
least a first
layer of insulating material; cutting an elastomer membrane to a size
sufficient to cover
the first layer and extend at least beyond one edge of the first layer;
heating the cut
elastomer membrane while separate from the first layer; and adhering the
heated
elastomer membrane onto the first layer.
[0008] Further in accordance with the present disclosure, there is provided
a
composite panel comprising: an in-plant assembly; an elastomer membrane; at
least
two layers of insulating panels, a first of the two layers laminated to the
elastomer
membrane; and an adhesive layer and backing sheet, the adhesive layer being on
a
second of the two layers of insulating panels.
DESCRIPTION OF THE DRAWINGS
[0009] Fig. 1 is a perspective view of a composite panel featuring an
insulating
material, in accordance with the present disclosure; and
[0010] Fig. 2 is an assembly view of composite panels; and
[0011] Fig. 3 is a schematic view of a method for manufacturing the
composite
panels of the present disclosure.
DETAILED DESCRIPTION
[0012] Referring to Fig. 1, there is illustrated at A a composite panel
according to the
present disclosure. The composite panel A has an elastomer membrane 1
positioned
onto a first layer 2 of insulating subpanels (e.g., such as polyisocyanurate
subpanels,
polystyrene subpanels (e.g., EPS subpanels), fiber subpanels, stone wool or
rock wool
subpanels, to name a few possibilities). A second layer 3 of insulating
subpanels is
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CA 02955951 2017-01-23
secured to the first layer 2 of insulating subpanels. A free portion 1A of the
elastomer
membrane 1 extends beyond edges of the first layer of insulating subpanels 2,
on two
sides. According to an embodiment, the first layer and the second layer 3 are
molded
into a monolithic piece.
[0013] The layers 2 and 3 of insulating subpanels (or the single molded
panel
emulating the combination of the layers 2 and 3) are also arranged to have
extensions,
as observed from Fig. 1. Indeed, this arrangement allows the interlocking of
adjacent
composite panels A. It is considered to provide an adhesive on the extensions
4 (ship
lap joint) to facilitate bonding of adjacent panels. The extensions 4 are
typically
between 0.5 inches and 3 inches (but all the way to 12 inches being
contemplated) to
allow a strong mechanical bond between adjacent composite panels A.
[0014] It is also considered to provide an adhesive layer 5 on the lower
exposed
surface of the layer 3 of the composite panel A, for instance with a backing
sheet 6 to
protect same. The backing sheet 6 would allow stacking of composite panels A,
during
storage and transportation, to ultimately be removed at the construction site.
However,
the composite panel shown in Fig. 1 may be without the adhesive layer 5, which
adhesive can be applied on site. As an embodiment, the adhesive is part of a
vapor-
barrier layer 5, with the exposed face of the vapor-barrier layer 5 exposing
adhesive, for
instance covered by a backing sheet 6. In such a case, the vapor-barrier layer
5 may
have extensions 5A on one side and at one end, in a many similar to the
extensions 4
in the layers 2 and 3. A suitable vapor-barrier layer 5 may have a high-
density
polyethylene top side (i.e., against the layer 3), woven or as a film. An
aluminum film is
another possible material for the top side of the vapor-barrier layer 5. The
underside,
i.e., facing downwardly with tacky adhesive, may be SBS (modified bitumen,
i.e.,
asphalt mixture with rubber modifiers and solvents). The vapor-barrier layer 5
is for
example a material selected according to ASTM D2178, ASTM E96.
[0015] It is also pointed out that a structural layer 6 may be provided
between the
elastomer 1 and the layer 2. For example, the structural layer 6 may be a
fiberboard
layer, etc.
[0016] Fig. 2 illustrates a pair of adjacent composite panels A, once
assembled, as
mated by the complementary edge geometries. The extension of the free portion
1A is
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CA 02955951 2017-01-23
useful as it allows to form a waterproof joint between adjacent composite
panels A,
when installed side by side. In particular, the free portion 1A is not backed
by
polyisocyanurate, whereby it can be blowtorched either self-standing upwardly,
or as
laid over the elastomer membrane 1 of the adjacent composite panel A, whereby
the
layer of elastomer membrane 1 backed to polyisocyanurate is not directly
welded. If
the layer 5 is a vapor-barrier layer 5, the extensions 5A may be used in the
manner
shown in Fig. 2 is create a vapor-barrier overlap at the junction between
panels A.
[0017] The composite panel A is entirely fabricated in plant, as opposed to
being
assembled on the construction site. Firstly, depending on the size of the
composite
panel A, an adhesive is deposited on the layers 2 and 3, to bond them together
with the
edge extensions. When assembling the layers 2 and 3, adhesive may be provided
on
both facing surfaces of the layers 2 and 3, to increase the bond between the
layers 2
and 3 and thus the tear resistance. There also results from this dual
application the
presence of pressure-sensitive adhesive on the extensions 4. As the adhesive
is being
applied, it is considered to apply the adhesive layer 5 to then add the
backing sheet 6.
The type of adhesive may differ (e.g., hot melt, urethane derivatives). The
layers 2 and
3 are connected right after application of the adhesive, whereby high-
efficient curing
adhesives can be used, whereas the adhesive layer 5 may be a pressure-
sensitive
adhesive that remains tacky, to provide adherence at the construction site.
Alternatively, a monolithic panel is molded into the shape of the combined
layers 2 and
3, with adhesive optionally applied to the extensions 4.
[0018] The insulating panels are typically 36" by 48", whereas the
elastomer comes
in rolls that are 36-40" wide. Hence, the arrangement of Fig. 3 is used at
assembly.
The composite panel A shown in Fig. 1 has two side-by-side insulating panels
(referred
to above as subpanels 2 or 3), thereby resulting in a 36" by 96" size, with
the elastomer
membrane 1 being rolled onto the top layer 2. This assembly method therefore
allows
even larger panels to be manufactured, from 36" by 96", to 36" by 192".
[0019] Once the layers 2 and 3 are assembled, the elastomer membrane 1 (or
equivalent) may be laminated to the layer 2. It may firstly be cut to
appropriate length.
The adhering may be done by heating the elastomer membrane 1 only and not the
panels 2 and 3 of polyisocyanurate. Indeed, in-plant assembly allows larger
equipment
to be used, as opposed to blow torches, and thus a high enough membrane
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CA 02955951 2017-01-23
temperature may be reached such that, as a whole, it may be deposited on the
layer 2
of insulating subpanels to form a solid structural bond. A press may then be
used to
laminate the elastomer membrane 1 into the layers 2 and 3. Other options are
considered, such as applying a roll pressure on the elastomer membrane 1, etc.
The
elastomer membrane 1 may be a multi-ply membrane, i.e., having one or more
layers
of the elastomer.
Moreover, on the construction site, an additional elastomer
membrane may be placed on top of the panels A, as additional waterproofing
layer.
[0020] Before
or after the lamination of the waterproof membrane 1, vapor-barrier
layer 5 (e.g., with backing layer 6) may be positioned on the layer 3, if the
layer 5 is a
vapor-barrier and not simply an adhesive layer. The vapor-barrier layer 5 may
have an
adhesive surface by which its bonds to the layer 3 and/or an adhesive may be
applied
to the layer 3 before laying or pressing the vapor-barrier layer 5 onto the
layer 3. An
appropriate size of the vapor-barrier 5 is used to form extensions 5A.
[0021] The
method for fabricating the composite panel A is performed in plant at
least by forming a first layer 2 of insulating material. The elastomer
membrane 1 is cut
to a size sufficient to cover the first layer 2 and extend at least beyond one
edge of the
first layer 2. The cut elastomer membrane 1 is heated while separate from the
first
layer 2. The heated elastomer membrane 1 is adhered onto the first layer 2.
[0022] It is
considered to make the composite panel with insulating materials other
than polyisocyanurate, such as foams of different natures, etc. The layers are
between
0.5" and 3.0" thick. The elastomer membrane 1 may be SBS.