Insulating and impervious roofing panels

• US 4,696,847 A
• Filed: 09/16/1986
• Issued: 09/29/1987
• Est. Priority Date: 10/29/1982
• Status: Expired due to Term

• Current Assignee: Isover Saint-Gobain
• Original Assignee: Isover Saint-Gobain
• Inventors: Boumendil, Jean-Paul, Cousin, Stephane
• Primary Examiner(s): Bell, James J.
• Application Number:
  US06/907,984
• Time in Patent Office: 378 Days
• Field of Search: 428/74, 428/280, 428/282, 428/297, 428/298, 428/302, 428/303, 428/340, 428/285, 428/489, 428/440, 428/920, 428/141, 428/142, 428/76, 428/192, 428/913
• US Class Current: 428/76
• CPC Class Codes: B32B 11/10 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 19/06 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2262/108 Rockwool fibres
• CPC Class Codes: B32B 2323/10 Polypropylene
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: E04D 3/351 at least one of the layers being composed of insulating material, e.g. fibre or foam material
• CPC Class Codes: Y10S 428/913 Material designed to be responsive to temperature, light, moisture
• CPC Class Codes: Y10S 428/92 Fire or heat protection feature
• CPC Class Codes: Y10T 156/1052 with cutting, punching, tearing or severing
• CPC Class Codes: Y10T 428/239 Complete cover or casing
• CPC Class Codes: Y10T 428/24777 Edge feature
• CPC Class Codes: Y10T 428/31641 Next to natural rubber, gum, oil, rosin, wax, bituminous or tarry residue
• CPC Class Codes: Y10T 428/31815 Of bituminous or tarry residue
• CPC Class Codes: Y10T 442/50 FELT FABRIC

Abstract

This invention relates to a fibrous panel and to a process and apparatus for its manufacture, the panel includes a dense felt mat (2) of mineral fibres having on at least one of its main surfaces an impervious covering (3, 7) consisting of a reinforcing film (3) of mineral fibres impregnated with a binder, for example bitumen, and bonded to the felt (2) by the binder, and having, on the external surface, a separating agent (7) glued to the film (3) by the binder, the agent (7) being self welding in the heat. The panels according to this invention are advantageous for the insulation and weatherproofing of roofs, especially those with only a slight slope, in particular on account of their reliability in use as well as that of the impervious coverings for which they serve as support.

Claims

1. A heat insulating and liquid impervious fibrous panel positionable between a roof with a slight slope and at least one hot applied bituminous coating or sheathing, comprising:

a mat consisting of a dense felt of mineral fibers bonded together by a first thermosetting binder finely dispersed in the felt, and a composite waterproof impervious covering comprising a reinforcing layer of mineral fibers impregnated with a second binder and glued by said second binder to said dense felt and, a sheet of separating agent capable of binding to the reinforcing layer by means of said second binder impregnating said reinforcing layer, and capable of selt hot welding.

2. Panel according to claim 1, wherein said second binder is a thermoplastic bitumen.

3. Panel according to claim 2 wherein said thermoplastic product has a viscosity imparting the following properties:

"ball and ring temperature" according to French standard T 66008 within the range of 70°

to 100°

C. and "penetrability" according to French standard T 66004 of from 10 to 50.

4. Panel according to claim 1, wherein said panel has borders and said reinforcing layer of mineral fibers comprises at least one warp of reinforcing threads of mineral fibers orientated in the direction of one of two main dimensions of the panel and orientated from one to the other of two edges covered with said border.

5. Panel according to claim 4, wherein said mineral fibers of the reinforcing layer have a diameter of from 6 to 20 μ

m.

6. Panel according to claim 1 wherein the mass per unit surface of the reinforcing layer is from 30 to 200 g/m².

7. Panel according to claim 2 wherein said second binder comprising a bitumen.

8. Panel according to claim 1, wherein said first binder is of the phenol formaldehyde type.

9. Panel according to claim 1, wherein said mat has a mass per unit volume of 120 to 250 kg/m³.

10. Panel according to claim 1, wherein the thickness of the felt mat is from 2 to 15 cm.

11. Panel according to claim 2 wherein said separating agent is a thermoplastic material having good dimensional stability up to a temperature at least equal to the "ball and ring" temperature of said second binder and fusible at a temperature enabling the panel to be hot coated with the impervious bituminous coating after the panel has been positioned on the roof to be treated.

12. Panel according to claim 11, wherein said thermoplastic material is at least miscible in said bituminous coating.

13. Panel according to claim 11, wherein said thermoplastic material has a melting temperature at least equal to the temperature at which the said second binder is capable of ensuring the bond of the reinforcing layer with the mat of felt.

14. Panel according to claim 11, wherein said thermoplastic material is at least miscible in the said second binder.

15. Panel according to claim 11, wherein said thermoplastic material belongs to the family of polyolefins and is preferably chosen from among polyethylenes and polypropylenes having no greater than a medium density.

16. Panel according to claim 11, wherein said sheet of separating agent has a thickness of from 5 to 20 μ

m.

17. Panel according to claim 1 wherein said composite covering comprising the reinforcing layer and sheet of separating agent covers one main surface of the panel and two opposite longitudinal surfaces thereof, as well as an overlap of a width of at least 2 cm on corresponding edges of a second main surface of the panel.

18. Panel according to claim 17, wherein said mat of felt has some material missing in a gap location provided for the overlap on the edges of the second main surface, the thickness of said gap in the material corresponding substantially to the thickness of the composite covering.

19. Panel according to claim 17, wherein longitudinal surfaces of said panel not reached by the overlap of the composite covering applied to the first main surface are covered by strips of said composite covering bonded thereto by means of said second binder and of a suitable form to cover surfaces substantially equivalent to those covered by the overlap of the longitudinal surfaces.

20. Panel according to claim 19, wherein the composite covering comprising the reinforcing layer and sheet of separating agent covers six surfaces of the mat of felt.