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GB2223520A - Insulated roofing panel - Google Patents

Insulated roofing panel Download PDF

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Publication number
GB2223520A
GB2223520A GB8918621A GB8918621A GB2223520A GB 2223520 A GB2223520 A GB 2223520A GB 8918621 A GB8918621 A GB 8918621A GB 8918621 A GB8918621 A GB 8918621A GB 2223520 A GB2223520 A GB 2223520A
Authority
GB
United Kingdom
Prior art keywords
roofing product
roofing
product
concrete
mass
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB8918621A
Other versions
GB2223520B (en
GB8918621D0 (en
Inventor
Lei-Pan Pan
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of GB8918621D0 publication Critical patent/GB8918621D0/en
Publication of GB2223520A publication Critical patent/GB2223520A/en
Application granted granted Critical
Publication of GB2223520B publication Critical patent/GB2223520B/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/288Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
    • E04C2/2885Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material with the insulating material being completely surrounded by, or embedded in, a stone-like material, e.g. the insulating material being discontinuous
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/003Machines or methods for applying the material to surfaces to form a permanent layer thereon to insulating material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/0068Embedding lost cores
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D11/00Roof covering, as far as not restricted to features covered by only one of groups E04D1/00 - E04D9/00; Roof covering in ways not provided for by groups E04D1/00 - E04D9/00, e.g. built-up roofs, elevated load-supporting roof coverings
    • E04D11/02Build-up roofs, i.e. consisting of two or more layers bonded together in situ, at least one of the layers being of watertight composition
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D13/00Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights
    • E04D13/16Insulating devices or arrangements in so far as the roof covering is concerned, e.g. characterised by the material or composition of the roof insulating material or its integration in the roof structure

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Building Environments (AREA)

Abstract

An insulated roofing panel has a core 14 of expanded polystyrene surrounded by a crust of concrete 12. The core 14 has grooves 16 and holes 18 which are filled by the surrounding concrete. <IMAGE>

Description

A ROOFING PRODUCT This invention relates to a roofing product, and in particular insulative roofing products.
The following insulative roofing products are known: (1) Asbestos type tiles: Most developed countries have legislated against the use of asbestos because of its harmful effect to human health.
(2) Hollow type tiles:- As there is, no air "convention effect" in the hollow part of the tile, heat will accumulate and cannot be dissipated. Roof-tops laid with a layer of such tiles cannot b used to walk on by people, and oozing will easily occur.
(3) Concrete foam tiles By using the process of shotcrete grouting, the whole roof-top is laid with a layer of 8-lO cm of concrete foam. The thermal insulation effect is better than that of hollow type tiles. However., this method is difficult to handle and in particular to lay. Its biggest dcfect is that the glal.ity of concrete foam is very fragile and may disintegrate under slight pressure. The material is also subject to weathering as time passes and is bygroscopic so as to cause oozing.
Roof-tops laid with such tiles cannot be used to walk on by people.
( Hard PU (High Density Polyurethane) type roofing: - As PU plastic material has a heat insulating effect, this current heat insulative products may he laid on top of another material or laid on the roof and covered on top with other material, or sandwiched in the middle with PU in a rigid form (the so called "sandwich type"). There are numerous varieties, however, they all share the same defects as those of concrete foam in that they are fragile, will absorb water and weather with time, leading to oozing. At the same time, its price is more expensive and its volume more bulky, and the roof-top is unusable for walking on by people after installation.
(5) Pleat screening paste type roofing:- This type is a kind of chemical coating material applied by spraying the material on to the surface of the roof-top. It will be effective initially but will lose the effect of reflecting heat when dust accumulates on its surface as time passes. Another problem is that with such application the roof-top cannot be used for walking on by people. It is also expensive.
(6) Fibre-Glass type roof ing:- This type of roofing is extremely expensive. Its defects are the same as those of the previous two types.
It is an object of the invention to provide an insulative roofing product having improved characteristics over known roofing products.
In accordance with the invention, a roofing product is provided in which the interior thereof is substantially of polystyrene insulating material.
Such is light, strong, and easy to apply, yet superior in thermal screening and water-proof ing. It will increase the usability of and decrease problems associated with roof-tops of buildings, since it will be possible for the occupier of the top-floor of a building to eliminate the twin problems of "heat" and "oozing" without reducing the usable areas of roof-tops, thus improving living conditions.
Such a roofing product has a very good thermal insulating effect. The polystyrene insulating material is relatively light and reluctant in combining with other materials, and has a flexible load strength sufficient to allow people to walk on the roofing product. The roofing product is not only thermally insulative, but also water-proof.
Suitably, the insulating material is expanded polystyrene (also known as Soly Foam Styropor).
Advantageously, the roofing product includes an internal mass of insulative material surrounded by a crust of concrete material. Preferably, the mass of insulative material is provided with a plura y of grooves in the upper and lower layers thereof, the plurality of grooves on the upper surface being offset from the plurality of grooves provided on the lower surface. The concrete during moulding fills these various grooves provided on the upper and lower surf aces, in order to strengthen the resultant outer crust of concrete.
Suitahly, the mass of insulative material has a plurality of holes passing completely therethrough from the upper to the lower surfaces thereof, and in particular the plurality of holes are situated within the grooves provided on the upper surface of the mass of insulative material.
Similarly, the concrete during moulding fills these holes, in order to provide a solid connection between the upper and lower surfaces of the resultant concrete crust, thereby strengthen the whole arrangement.
Suitably, the mass of insulative material occupies at least 80% (and more preferably at least 90%, and most preferably at least 95tut) of the plan cross-sectional area of the roofing product.
The invention will now be described by way of reference to the accompanying drawings, in which: Fibre 1. is a perspective view of a roofing product in accordance with the invention; Figure 2 is a perspective view of an internal component of the roofing product of Figure 1; Figure 3 is a side cross-sectional view of product of Figure 1; Figure 4 is an underneath cross-sectional view of the product of Figure 1; Figure 5 is a plan cross-sectional view of the product of Figure 1; Figure 6 is a cross-sectional side view of a roof with roofing products as shown in Figure 1; and Figures 7A to E show the manufacturing steps of a roofing product as shown in Figure 1.
The roofing product shown in Figure 1 is in the form of a tile or brick 10 which comprises an outer shell of concrete 12 provided around an internal component 14, details of which are shown in Figures 2 to 5.
The internal component 14 shown in Figure 2 comprises a slab of expanded Polystyrene (EPS - also known as Poly Foam Styropor) with a series of criss-cross channels 16 on the upper and lower surf aces thereof, together with four holes 18 provided in the upper series of criss-cross channels, which holes 18 pass completely through to the bottom of the component. The channels 16 on the upper surface are offset from the channels 16 on the lower surface.The channels 16 and holes 18 are provided in order to strength the outer shell of concrete, since connecting plugs of concrete between the upper and lower layers of concrete are formed in the holes lS, and the upper and lower layers of concrete are rigidly secured to the upper and lower layers of the internal component respectively due to concrete filling the channels 16.
In Figure 6, an arrangement. showing use of the roofing product is shown, and in particular two roofing products 10 are shown side by side on a roof 20, the two products 10 being connected together (and to the side wall of the roof 20) by an appropriate adhesive mixture 22 (such as a water-proof cement or an elastic and long-lived silicone glue).
The roofing product of Figure 1 is manufactured using the internal component shown in Figure 2 by the manufacturing steps shown in Figures 7A to E In particular, a mould box 30 having a base 31 and sides 33 as shown in Figure 7A is used upon which a lower layer 32 of concrete is formed (see Figure 7B), whereafter the internal component 14 of Figure 2 is placed within the mould box and pressed onto the layer 32 of concrete such that concrete fills the channels 16 on the bottom of the internal component (see Figure 7C), and finally a final layer 34 of concrete is placed in the mould box 30 on top of the internal component 14, which concrete also firstly moves around the sides of the internal component to form the sides 35 of the roofing product, secondly fills up the holes 18 thereof, and thereby provides connecting plugs between the upper and lower concrete layers 32 and 34 of the roofing product 10, and thirdly fills the channels 16 on the top of the internal component. The sides 33 of the mould box 30 are then removed to reveal the formed roofing product 10 which is then ready for removal (see Figure 7E) from the base 31.
The invention will now be described in greater detail, and in particular the deign, function and manufacturing aspects of the invention will be described.
Design of the roofing product is as follows: (I) Size:- Length : 300 mm Width : 300 mm Thickness: 38 mm (or other sizes) according to need.
(2) Material:- cement, sand and EPS internal component of specified size.
(3) The thickness of the six outer surfaces of the roofing product crust (1 top, 1 bottom and 4 lateral sides) is 5 mm; the whole interior is filled with the high dens.ity EPS internal component, (4) The EPS internal component is moulded to the specified measurement and shape, and then formed into the interior of the roofing product.
(5) To increase the srenth of the outer surfaces. of the roofing product (i.e. the crust), a criss-cross rectangular internal component is used having grooves lG concaved inwards on the top and bottom layers, which causes during moulding the internal top and bottom surfaces of the crust to be formed with ribs thereby providing an arrangement equivalent to a "Grillage beam", in other words distributing the pressure on the roofing product surface evenly from 300 mm down to 75 rnm.
Also there are at least four holes 18 piercing through the EPS internal components from the top to bottom layer which form connecting plugs when the mould box is filled. The "Grillage beam" and plugs crust arrangement needs to be reverse designed to make it fit into the concaves of the EPS internal component, and in this regard the EPS internal component will become the "base mould". When the mould box is filled up with cement paste, the inner shape of the crust may be set in a single step.
Function of the roofing product is as follows: (1) Although the apparent conductive area of the roofing product is 300 mm x 300 mm, heat can practically only he conducted to the bottom part (that is the floor of the roof-top) from the four sides of the crust of the roofing product (5 mm in width), and the four connecting plugs of 8 mm in diameter each. That is to say the effective conductive area of the roofing product is only 1/28 of the total roofing product area. The rest of the heat, being unable to permeate through the interior of the EPS "screening layer", can only stay at the surface of the roofing product, exerting no influence at the bottom (in other words the original top layer of the roof-top).
(2) For the same reason, the heat absorbed by the surface of the roofing product 10 can, since it is in contact with moving air, be quickly dissipated, whereas other known heat insulating materials require a much longer time to dissipate the heat accumulated at their interior.
(3) As the body (material) of the roofing product is largely made up of EPS of very light specific gravity, its weight is only about 2/5th of roofing products of the same size. Therefore, cost for materials, transportation and application is greatly reduced.
(4) As the mould for producing the roofing product is specifically designed, the surf ace of the roofing product is smooth and good-looking (and in fact could also be provided with an ornamental surface design), and can carry a load of 220 kilogram without danger of disintegration. This is unrivaled by other insulating roofing materials.
(5) Since, apart from the four sides and the four connecting plugs, 27/28 of the roofing product body is absolutely water-proof EPS, one need only fill up the gaps between adjacent roofing products with water-proof cement (or elastic and long-lived silicone glue) during the process of application of the roofing products to a roof to ac.hieve an ooze-proof roof-top.
Manufacturing of the roofing product is as follows:- (S) Production eguipment:- (a) raw material mixer.
(b) mould: made of aluminium alloy, and each mould set for the roofing product, including one bottom board, four templets, and four fixing locks.
(2) Basic materials: (a) hydrophobic cement (b) fine sand (C) EPS internal component (3) Manufacturing steps: (a) fix the four templets onto the bottom board with the fixing locks (see Figure 7h).
(b) apply a layer of S mm thick mixed cement paste inside the mould (see Figure 7B).
(c) place the pre-made EPS internal component inside the middle of the mould with a gap df 5 mm from each of the four sides of the mould (see Figure 7C).
(d) fill up the space between the four side frames and the EPS internal component until tho BPG internal component is covered up; then top up to the surface of the mould (see Figure 7D).
(e) apply a little vibration.
(f) smooth out the cement paste at the top of the mould.
(g) dry it naturally until solidification.
(h) after a lapse of about 24 hours the cement solidifies, the roof product is then pulled out from the mould and the process is completed (see Figure 7E).
For mass production, the mould should be modified to a standing type so as to produce 6 to 8 pieces at a time.
Comparison tests between the roofing product of the present invention and known roofing products have been conducted, and the results thereof will be ascertained from the following table: COMPARISON OF DIFFERENT BUILDING MATERIAL
- - w pglysical Oulk Insu- Non- Ag 11cal Slless,ult Wualilef Ctt * Outside Piopeiy 0dfls1Y lulecl Iniscl s w::ricr RuslSv ol L)U(biti ghNlC I Ill!i\l sll{ecl 84somp A canto St C OucDLllu lullon product lion eennaly luro 1 C Asbestos MOXO iX 0 0 ~~ flock WooiBoardMOX ;0 t V GIasWooILO > < (O. ~~~ G)assWoal -' ^"o 0 pE Foam L O (i) i x x A Foam PSFoarn L 0 X X 0 X. A L,Y PUfli0tdFo(Ifl L (i) X 0 x 0 flC hoard L O O O 0 --- (i)
Roofing prodct' of present MOoQoo M e 0 0 0 0 # EXCELLENT # GOOD # FAIR XNO GOOD X H M MEDIAN L LOW A thermal insulation test was also conducted on a roofing product in accordance with the present invention, namely heat was applied on one surface for six hours at 360C, whereafter the temperature of the other side was measured and found to be 30.50C (room temperature was 29.50C), The roofing product of the invention has superior heat insulation properties due to the interior construction of the product.In particular, a quasi vacuum thermal insulation layer reduces the superficial area of thermal conduction to 1/28, thus obtaining ideal thermal insulation, In particular, the internally ribbed crust of the roofing product together with the internal connecting plugs act like grillage beams of a building structure, and in conseTuence the flextural load of the roofing product is greatly enhanced without having the fragility normally found in ordinary roof-top insulation materials.
The roofing product is extremely water-proof, due to the fact that the internal construction, which is formed of expanded polystyrene is 100% water-proof. The materials of the roofing product are simple, namely cement, sand and expanded polystyrene, and therefore the roofing product is simple and relatively cheap to manufacture. Furthermore, its weight is light, and in particular is about 2/5th of that of a cement roofing product of the same volume.

Claims (12)

C t A I M S:
1. A roof ing product in which the interior thereof is substantially of polystyrene insulating material.
2. A roofing product as claimed in Claim 1, wherein the insulating material is expanded polystyrene.
A. A rourig 9 product aG claimed in to.r Claim 1 or 2, wherein the roofing product includes an internal mass of insulative material, surrounded by a crust of concrete material.
4. A roofing product as claimed in Claim 3, wherein the mass of insulative material is provided with a plurality of grooves in the upper and lower layers thereof.
5. A roofing product as claimed in Claim 4, wherein the plurality of grooves on the upper surface are offset from the plurality of grooves provided on the lower surface.
6. A roofing product as claimed in either Claim 4 or 5, wherein the crust of concrete fills the plurality of grooves provided on the upper and lower surfaces.
7. A roofing product as claimed in any one of Claim 3 to 6, wherein the mass of insulative material has a plurality of holes passing completely therethrough from the upper to the lower surfaces thereof.
8. A roofing product as claimed in Claim 7, wherein the plurality of holes are situated within the plurality of grooves provided on the upper surface.
9. A roofing product as claimed in either Claim 7 or 8, wherein the crust of concrete fills the plurality of holes in the mass of insulative material.
10. A roofing product as claimed in any preceding Claim, wherein the mass of insulative material occupies at least 80% of the plan cross-sectional area of the roofing product.
11. A roofing product as claimed in Claim 10, wherein the mass of insulative material covers at least 90E of the plan cross-sectional area of the roofing product.
12. A roofing product as claimed in Claim ll, wherein the mass of insulative material occupies at least 95 of the plan cross-sectional area of the roofing product.
GB8918621A 1988-08-15 1989-08-15 A roofing product Expired - Fee Related GB2223520B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CN88209706U CN2041702U (en) 1988-08-15 1988-08-15 Nest type vacuum heat insulation brick

Publications (3)

Publication Number Publication Date
GB8918621D0 GB8918621D0 (en) 1989-09-27
GB2223520A true GB2223520A (en) 1990-04-11
GB2223520B GB2223520B (en) 1993-07-21

Family

ID=4843300

Family Applications (1)

Application Number Title Priority Date Filing Date
GB8918621A Expired - Fee Related GB2223520B (en) 1988-08-15 1989-08-15 A roofing product

Country Status (2)

Country Link
CN (1) CN2041702U (en)
GB (1) GB2223520B (en)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE9316864U1 (en) * 1993-11-04 1994-01-13 Bruckschlögl, Michael, 91161 Hilpoltstein Non-load-bearing ceiling element
WO2007040461A1 (en) * 2005-10-05 2007-04-12 Jee Keng James Lim Composite cement-foam panel and roof deck system
WO2008006917A1 (en) * 2006-07-11 2008-01-17 Bestile, S.L. Paving and cladding tile
WO2008143591A1 (en) 2007-05-18 2008-11-27 Jee Keng James Lim Composite cement panel

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102006061085A1 (en) * 2006-12-22 2008-06-26 BSH Bosch und Siemens Hausgeräte GmbH The refrigerator

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB955156A (en) * 1960-01-19 1964-04-15 Eric Carl Latscher Latka Improvements in or relating to building slabs
GB1020917A (en) * 1962-12-12 1966-02-23 Poron Insulation Ltd Building panel
GB1199861A (en) * 1968-01-03 1970-07-22 Elkalite Ltd Composite Building Panel
EP0000837A1 (en) * 1977-08-15 1979-02-21 Graeme John Tilly Load bearing wall panels and method of manufacture thereof

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB955156A (en) * 1960-01-19 1964-04-15 Eric Carl Latscher Latka Improvements in or relating to building slabs
GB1020917A (en) * 1962-12-12 1966-02-23 Poron Insulation Ltd Building panel
GB1199861A (en) * 1968-01-03 1970-07-22 Elkalite Ltd Composite Building Panel
EP0000837A1 (en) * 1977-08-15 1979-02-21 Graeme John Tilly Load bearing wall panels and method of manufacture thereof

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE9316864U1 (en) * 1993-11-04 1994-01-13 Bruckschlögl, Michael, 91161 Hilpoltstein Non-load-bearing ceiling element
WO2007040461A1 (en) * 2005-10-05 2007-04-12 Jee Keng James Lim Composite cement-foam panel and roof deck system
WO2008006917A1 (en) * 2006-07-11 2008-01-17 Bestile, S.L. Paving and cladding tile
ES2299362A1 (en) * 2006-07-11 2008-05-16 Bertile, S.L. Paving and cladding tile
WO2008143591A1 (en) 2007-05-18 2008-11-27 Jee Keng James Lim Composite cement panel
EP2167752A1 (en) * 2007-05-18 2010-03-31 Lim, Jee Keng James Composite cement panel
US20100189953A1 (en) * 2007-05-18 2010-07-29 Jee Keng James Lim Composite cement panel
EP2167752A4 (en) * 2007-05-18 2012-04-11 Lim Jee Keng James Composite cement panel
US8438806B2 (en) * 2007-05-18 2013-05-14 Jee Keng James Lim Composite cement panel
TWI418690B (en) * 2007-05-18 2013-12-11 Jee Keng James Lim Composite panel for rooftop surface and method of making the same
AU2008253759B2 (en) * 2007-05-18 2014-08-28 Jee Keng James Lim Composite cement panel
CN101743365B (en) * 2007-05-18 2014-11-26 林儿庆 Composite cement panel

Also Published As

Publication number Publication date
CN2041702U (en) 1989-07-26
GB2223520B (en) 1993-07-21
GB8918621D0 (en) 1989-09-27

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Legal Events

Date Code Title Description
WAP Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1)
911B Proceeding under rule 110 of the patent rules 1990
911A Proceeding under rule 110(4) of the patent rules 1990
PCNP Patent ceased through non-payment of renewal fee

Effective date: 19931021