High-performance torchable thermal insulating panel for buildings roofs

Abstract

Separating membrane of plastic material, made up of a bossed and waterproof sheet which is coupled with a permeable base layer. The bosses are of the cylindrical type with a double diameter and have such a shape and arrangement as to feature improved adhesion on both faces. The gripping of the adhesive is increased in order to obtain greater tear strength, on the upper face, and at the same time increases the area of contact with the base layer for a greater resistance to delamination on the lower face. In particular, inside each chamber there is an internal crown, which divides it like a necking into two superimposed compartments having the same diameter, wherein the first compartment has a depth amounting to at least of the total. A production process for obtaining the membrane is also disclosed.

Claims

1. A thermal insulating panel for a roof of a building, the thermal insulating panel comprising: an intermediate layer of rigid polyurethane foam having an upper face and a lower face; a first multi-layer coating coupled to the upper face of said intermediate layer; and a second multi-layer coating coupled to the lower face of said intermediate layer, each of said first and second multi-layered coatings being gas-tight, each of said first and second multi-layered coatings comprising layers arranged sequentially from the intermediate layer as follows: a layer of metallized polyester film; a layer of polyethylene film; a layer of moisture-proof paper; a layer of film of a bituminous compound of polymer bitumen; and a layer of a non-woven polypropylene fabric, wherein said layer of metallized polyester film is affixed to said intermediate insulating layer.

2. The thermal insulating layer of claim 1, wherein said layer of metallized polyester film has a thickness between 10 microns and 30 microns.

3. The thermal insulating layer of claim 1, wherein said layer of polythylene film has a density of between 10 grams per square meter and 14 grams per square meter.

4. The thermal insulating layer of claim 1, wherein said layer of moisture-proof paper has a density of between 100 grams per square meter and 140 grams per square meter.

5. The thermal insulating layer of claim 1, wherein said layer of film of the bituminous compound has a density between 200 grams per square meter and 2500 grams per square meter.

6. The thermal insulating layer of claim 1, wherein said layer of the non-woven polypropylene fabric has a density of between 20 grams per square meter and 50 grams per square meter.

7. The thermal insulating layer of claim 1, wherein said layer of metallized polyester film has a thickness of 12 microns and a density of 12 grams per square meter.

8. The thermal insulating layer of claim 1, wherein said layer of polyethylene film has a density of 12 grams per square meter.

9. The thermal insulating layer of claim 1, wherein said layer of the moisture-proof paper sheet has a density of 120 grams per square meter.

10. The thermal insulating layer of claim 1, wherein said layer of the film of the bituminous compound has a density of 250 grams per square meter.

11. The thermal insulating layer of claim 1, wherein said layer of the non-woven polypropylene fabric has a density of 40 grams per square meter.

Description

CONTENT OF THE DRAWINGS

(1) FIG. 1 shows a perspective view of the high-performance torchable thermal insulating panel for buildings roofs according to the present invention;

(2) FIG. 2 shows a plan view from above of the high-performance torchable thermal insulating panel for buildings roofs according to the present invention in which the various layers making up the panel and the multi-layer coating are presented;

(3) FIG. 3 shows a front side view of the high-performance torchable thermal insulating panel for buildings roofs according to the present invention in which the various layers making up the panel and the multi-layer coating are presented.

PRACTICAL EMBODIMENT OF THE INVENTION

(4) Referring without limits also to the content of the drawings as from the representations as in FIGS. 1 to 3, a high-performance torchable thermal insulating panel (1) for buildings roofs is described which in the embodiment described, which is a preferred solution as from the representations as in FIGS. 2 to 3, consists of a multi-layer sandwich comprising an intermediate insulating layer (2) of thermal insulating material which forms a shaped body of rigid polyurethane foam (PUR), or of an equivalent material, preferably providing that the thermal insulating material of which the intermediate insulating layer (2) of the thermal insulating panel (1) according to the present invention is made up is rigid polyisocyanurate foam (PIR), polyiso, given the high thermal insulation characteristics of the latter. In the embodiment described and preferably, the intermediate insulating layer (2) forms a parallelepiped-shaped body with flat faces in which the upper face (21) and the parallel, opposite and symmetrical lower face (22) are rectangular and have a greater surface area with respect to the remaining side faces (23) which delimit the perimeter of the thermal insulating panel (1), the distance between the upper face (21) and the lower face (22) being equal to the thickness of the intermediate insulating layer (2), the determination of said thickness directly influencing the thermal yield of the whole thermal insulating panel (1). Although it is preferable that the shape of the intermediate insulating layer (2) is, as described, a parallelepiped, it is provided that the shape of the intermediate insulating layer (2) which directly determines the overall shape of the thermal insulating panel (1), can be different from a parallelepiped provided that it enables the adjacent positioning of the thermal insulating panels (1) when laid to constitute the insulating roofing of the building roof.

(5) The thermal insulating panel (1) according to the present invention, both in correspondence of the upper face (21) and in correspondence of the lower face (22) is provided with a multi-layer coating (3) which covers up completely the surface area of the upper face (21) and of the lower face (22) of the intermediate insulating layer (2) with which it is associated. The association of the multi-layer coating (3) with the upper face (21) and with the lower face (22) of the intermediate insulating layer (2) of the thermal insulating panel (1) occurs according to the prior art during the production phase of the latter, preferably using the adhesive properties of the polyurethane foam of the intermediate insulating layer (2).

(6) In more detail of the embodiment described, as represented in FIGS. 2 to 3, the multi-layer coating (3) is made by coupling a multitude of layers of material each with specific technical features. In particular, it is provided that the multi-layer coating (3) is made by coupling at least the following layers:

(7) a) a first layer (31), which is provided to be the one that will be directly in contact, being associated with it, with the upper face (21) and with the lower face (22) of the intermediate insulating layer (2), said first layer (31) consisting of a metallized polyester film having a thickness preferably between 10 microns and 30 microns, the optimal thickness of the metallized polyester film making up the first layer (31) being of 12 microns with a grammage of 17 g/m.sup.2 (grams per square meter). The first layer (31) making up the multi-layer coating (3) is made for the purpose of arranging a first barrier layer that opposes the spreading of the gas which in time is released from the intermediate insulating layer (2) towards the external environment and simultaneously the counter-spreading of the external atmosphere towards the inside of the intermediate insulating layer (2) itself. The metallized polyester film used for the purpose of making the first layer (31) of the multi-layer coating (2) is of the known type and consists of a polyester film which is subjected to a metallization process consisting, as known, in arranging a very thin aluminium layer on the flexible polymer substrate made up of the polyester film, said process being carried out in a known way by means of a metallizing device in which one carries out the evaporation/sublimation of the metal in a vacuum condition while making pass the flexible polymer substrate made up of the polyester film.
b) a second layer (32), coupled according to a known art to said first layer (31), consisting of a polyethylene film, of the known type, having a grammage preferably between 10 g/m.sup.2 and 14 g/m.sup.2, the optimal grammage corresponding to 12 g/m.sup.2.
c) a third layer (33), coupled according to a known art to said second layer (32), consisting of a sheet of moisture-proof paper, of the known type, having a grammage preferably between 100 g/m.sup.2 and 140 g/m.sup.2, the optimal grammage corresponding to 120 g/m.sup.2.
d) a fourth layer (34), coupled according to a known art to said third layer (33), consisting of a film of bituminous compound, of the known type, having a grammage preferably between 200 g/m.sup.2 and 2500 g/m.sup.2, the optimal grammage corresponding to 250 g/m.sup.2. The bituminous compound constituting the fourth layer (34) is a polymeric bitumen of the known type obtained by mixing a bitumen and a polymer in such a way that the polymer component, which is notoriously added to the bitumen in a weight percentage definitely lower than that of the bitumen, is however intended to substantially modify the mechanical behaviour of the bitumen improving its characteristics. The fourth layer (34) is made for the purpose both of ensuring in any case a high degree of water-tightness of the thermal insulating panel (1) and for the purpose of facilitating the adhesion of the known thermoplastic membranes applied by flame torching which are traditionally arranged for covering the thermal insulating roofing in the realization of the multi-layer structure of the roof.
e) a fifth layer (35), coupled according to a known art to said fourth layer (34), consisting of a non-woven polypropylene fabric, of the known type, having a grammage preferably between 20 g/m.sup.2 and 50 g/m.sup.2, the optimal grammage corresponding to 40 g/m.sup.2.

(8) In this way, the multi-layer coating (3) with which the intermediate insulating layer (2) of the thermal insulating panel (1) according to the present invention is provided, carries out in an innovative way the function of enabling the gas-tightness of the intermediate insulating layer (2), realizing a gas-tight barrier which effectively opposes the spreading of the gas which in time is released from the intermediate insulating layer (2) towards the external environment and simultaneously the counter-spreading of the external atmosphere towards the inside of the intermediate insulating layer (2) so as to allow for the duration in time of the thermal insulating characteristics of the intermediate insulating layer (2). Furthermore, the multi-layer coating (3) with which the intermediate insulating layer (2) of the thermal insulating panel (1) according to the present invention is provided, also carries out the function of enabling an improved and easy adhesion of the thermoplastic membranes applied by flame torching which are traditionally arranged for the water-tightness of the building roof.

(9) In more detail of the embodiment described, the thermal insulating panel according to the present invention, thanks to its innovative structure and in particular thanks to the provided constitution of the multi-layer structure which makes up the multi-layer coating, allows to carry out both the gas-tightness function and the function of making the thermal insulating panel (1) torchable. The first function, i.e. gas-tightness, carried out by the multi-layer coating (3) according to the invention, is carried out in particular by the coupling: of the first layer (31) consisting of the metallized polyester film; of the second layer (32) consisting of the polyethylene film; and of the third layer (33) consisting of the moisture-proof paper sheet. Furthermore, the second function, consisting of the facilitation and of the improvement of adhesion, by means of torching, to the thermal insulating panel (1) of the thermoplastic membranes used in the making of buildings roofs, which function is also enabled in particular by the multi-layer coating (3) according to the invention, is carried out in particular by coupling the fourth layer (34), consisting of the bituminous compound film, to the fifth layer (35) consisting of the non-woven polypropylene fabric. Furthermore, the particular structure of the multi-layer coating (3) is such as to effectively counteract the deformation tendency of the intermediate insulating layer providing the thermal insulating panel with a suitable shape and dimensional stability.

(10) An alternative solution to the previous solution of a thermal insulating panel (1), which is reasonably subject to lower realization costs, consists of a multi-layer coating (3) which is substantially made up of three layers instead of the five layers provided. More particularly said multi-layer coating (3) comprises: at least one layer consisting of a metallized polyester film, said metallized polyester film having a thickness between 10 microns and 30 microns; at least one layer consisting of a polymer bitumen film having a grammage between 200 grams per square meter and 2500 grams per square meter; a layer consisting of a non-woven polypropylene fabric, wherein the layer consisting of the metallized polyester film is coupled to the intermediate insulating layer (2), said non-woven polypropylene fabric having a grammage between 20 grams per square meter and 50 grams per square meter.

REFERENCE

(11) (1) Thermal insulating panel

(12) (2) intermediate insulating layer

(13) (21) upper face

(14) (22) lower face

(15) (23) side faces

(16) (3) multi-layer coating

(17) (31) first layer

(18) (32) second layer

(19) (33) third layer

(20) (34) fourth layer

(21) (35) fifth layer