An insulating composite panel (ICP) 100, has an initial thermal resistance (R value) greater than about 50 ft2·° F.·h/Btu (8.8 K·m2/W) at a thickness less than 2.0 in (51 mm). The ICP is preassembled with a vacuum insulation panel (VIP) 102 protected by a lower rigid cover board 104 adhered to a low
An insulating composite panel (ICP) 100, has an initial thermal resistance (R value) greater than about 50 ft2·° F.·h/Btu (8.8 K·m2/W) at a thickness less than 2.0 in (51 mm). The ICP is preassembled with a vacuum insulation panel (VIP) 102 protected by a lower rigid cover board 104 adhered to a lower surface of the VIP by a lower grid of adhesive ribbons 108, and by an upper rigid cover board 106 adhered to an upper surface of the VIP by an upper grid of adhesive ribbons 110. Each of the adhesive grids 108, 110 is augmented by a respective continuous ribbon of adhesive 112, 114 along the entire perimeter of each respective interface between the VIP 102 and each respective cover board 104, 106. The ICP has high resistance to wind uplift, mold, and fire, and low mass per unit area.
대표청구항▼
1. An insulating composite panel (ICP) for use on building roofs, comprising: a prefabricated assembly having a thickness less than 3.0 inches (76 mm) and an initial thermal resistance (R value) greater than 30 degrees Fahrenheit-square foot-hour per Btu (30° F.·ft2·h/Btu) (5.3 K·m2/W), wherein the
1. An insulating composite panel (ICP) for use on building roofs, comprising: a prefabricated assembly having a thickness less than 3.0 inches (76 mm) and an initial thermal resistance (R value) greater than 30 degrees Fahrenheit-square foot-hour per Btu (30° F.·ft2·h/Btu) (5.3 K·m2/W), wherein the prefabricated assembly includes: a vacuum insulation panel (VIP) comprising: a) a substantially evacuated and hermetically sealed enclosure, with walls made of a high gas barrier material, in an approximately rectangular prismatic shape with low thickness/width and thickness/length ratios, andb) an internal rigid or semi-rigid core for keeping enclosure walls from collapsing while evacuated;a lower rigid cover board adhered to a lower surface of the VIP, andan upper rigid cover board adhered to an upper surface of the VIP;and wherein: the prefabricated assembly is adapted for maintaining its integrity at a wind uplift pressure of at least 120 pounds-force per square foot (5.75 KPa) according to ANSI/FM 4474 Appendix B: Simulated Wind Uplift Pull Test Procedure, by means comprising a continuous ribbon of adhesive along the entire length-width perimeter of each of the two interfaces between VIP and rigid cover board. 2. The ICP of claim 1, wherein the prefabricated assembly has a thickness less than 2.0 inches (51 mm) and an initial R value greater than about 50° F.·ft2·h/Btu (8.8 K·m2/W). 3. The ICP of claim 1, wherein: the prefabricated assembly is further adapted for maintaining its integrity at a wind uplift pressure of at least 120 pounds-force per square foot (5.75 KPa) according to ANSI/FM Appendix B: Simulated Wind Uplift Pull test Procedure, by means comprising a grid of adhesive ribbons at each of the two interfaces between VIP and rigid cover board. 4. The ICP of claim 1, wherein the adhesive is a hot melt adhesive. 5. The ICP of claim 1, wherein at least one of the rigid cover boards is selected for physical properties including no less than a Class A fire resistance as defined by Underwriter Laboratories standard UL790. 6. The ICP of claim 1, wherein at least one of the rigid cover boards is selected for physical properties including a mold resistance rating no less than 10 according to ASTM test method D3273. 7. The ICP of claim 1, wherein the prefabricated assembly has a mass per unit area of less than 3.0 pounds per square foot (14.7 kg/m2). 8. The ICP of claim 1, wherein one or both of the rigid cover boards comprise more than 50% by mass of a polymer. 9. The ICP of claim 8, wherein the polymer belongs to the class of polyurethanes. 10. The ICP of claim 8, wherein the polymer is polyisocyanurate (PIR). 11. The ICP of claim 8, wherein the polymer is in the form of a closed-cell foam. 12. The ICP of claim 11, wherein both of the rigid cover boards have a bulk density between about 12 and 31 pounds per cubic foot (between about 200 and 500 kg/m3). 13. The ICP of claim 1, wherein one or both of the rigid cover boards comprise more than 50% by volume of gypsum. 14. The ICP of claim 13, wherein the gypsum is reinforced by one or more types of fibrous material. 15. An insulating composite panel (ICP) for use on building roofs, comprising: a prefabricated assembly having a thickness less than 3.0 inches (76 mm) and an initial thermal resistance (R value) greater than 30 degrees Fahrenheit-square foot-hour per Btu (30° F.·ft2·h/Btu) (5.3 K·m2/W), wherein the prefabricated assembly includes: a vacuum insulation panel (VIP) comprising: a) a substantially evacuated and hermetically sealed enclosure with walls made of a high gas barrier material in an approximately rectangular prismatic shape with low thickness/width and thickness/length ratios, andb) an internal rigid or semi-rigid core for keeping enclosure walls from collapsing while evacuated;a lower rigid cover board adhered to a lower surface of the VIP, andan upper rigid cover board adhered to an upper surface of the VIP;and wherein: the prefabricated assembly is adapted for maintaining its integrity at a wind uplift pressure of about 180 pounds-force per square foot (8.6 KPa) according to ANSI/FM 4474 Appendix B: Simulated Wind Uplift Pull Test Procedure, by means comprising one or more U-shaped clamps dimensioned to fit snugly over the edges of the ICP. 16. The ICP of claim 1, wherein the prefabricated assembly is installed on top of a roof deck, such that: the lower rigid cover board is adhered to the roof deck without using mechanical fasteners; andan upper surface of the upper rigid cover board is adhered to a roofing membrane. 17. The ICP of claim 16 wherein the ICP is preassembled in a facility that is remote from sites where the ICP is to be installed. 18. An insulating building roof based on vacuum insulation panel (VIP) roofing insulation, the insulating roof comprising: a plurality of insulating composite panels (ICPs) that are adhered to a top surface of a deck of the roof, and are adhered to a bottom surface of a roofing membrane; wherein each ICP was pre-assembled in a facility that is remote from the building roof, and comprises: a prefabricated assembly having a mass per unit area less than 3.0 pounds per square foot (14.7 kg/m2), a thickness less than 2.0 inches (51 mm), and an initial thermal resistance (R value) greater than about 50° F.·ft2·h/Btu (8.8 K·m2/W), wherein the prefabricated assembly includes: a vacuum insulation panel (VIP) comprising: a) a substantially evacuated and hermetically sealed enclosure with walls made of a high gas barrier material in an approximately rectangular prismatic shape with low thickness/width and thickness/length ratios, andb) an internal rigid or semi-rigid core for keeping enclosure walls from collapsing while evacuated;a lower rigid cover board adhered to a lower surface of the VIP, andan upper rigid cover board adhered to an upper surface of the VIP. 19. The ICP of claim 15, wherein the prefabricated assembly is installed on top of a roof deck, such that: the lower rigid cover board is adhered to the roof deck without using mechanical fasteners; andan upper surface of the upper rigid cover board is adhered to a roofing membrane.
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