Composite water-resistant panels

Abstract

A composite panel comprising: a metal decking ( 1 ), optionally pre-coated with a decorative finish on its bottom surface a profiled metal top sheet ( 3 ) provided with a pre-laminated, waterproof, membranous layer on its top surface, an insulating layer ( 2 ) sandwiched between the top surface of the metal decking ( 1 ) and the bottom surface of the metal top sheet ( 3 ) and means ( 5, 7 ) for connecting the panel to a frame work ( 4 ) and/or another composite panel to form a substantially water resistant building or structure.

1 . A composite panel comprising: 
 a metal decking ( 1 ), optionally pre-coated with a decorative finish on its bottom surface a profiled metal top sheet ( 3 ) provided with a pre-laminated, waterproof, membranous layer on its top surface, an insulating layer ( 21 ) sandwiched between the top surface of the metal decking ( 1 ) and the bottom surface of the metal top sheet ( 3 ) and means ( 5 ,  7 ) for connecting the panel to a framework ( 4 ) and/or another composite panel to form a substantially water resistant building or structure.    
   
   
       2 . A composite panel as claimed in  claim 1  characterised in that the insulating layer comprises one or more of; particle board, mineral wool and polymeric foams.  
   
   
       3 . A composite panel as claimed in  claim 1  characterised in that the insulating layer is chemically bonded to the metal decking and/or the metal top sheet.  
   
   
       4 . A composite panel as claimed in  claim 2  characterised in that the insulating layer comprises polymeric foam injected into a space between the top surface of the metal decking and the bottom surface of the metal top sheet.  
   
   
       5 . A composite panel as claimed in  claim 1  characterised in that the panel is configured for use in the construction of a flat roof.  
   
   
       6 . A composite panel as claimed in  claim 1  characterised in that the panel is configured for use in the construction of guttering.  
   
   
       7 . A composite panel as claimed in  claim 1  wherein the waterproof membranous material is selected from; styrene butadiene modified bitumen, atactic polypropylene modified bitumen, polyalphaolefin modified bitumen, ethylene propylenediene monomer, chlorosulphonated polyethylene, polyvinyl chloride, copolymer alloys, polyisobutylene, butadiene acrylonitrile alloys and nitrile butadiene polymers, ethylene interpolymer, polyepichlorohydrin, chlorinated polyethylene or neoprene (chloroprene).  
   
   
       8 . A method for the manufacture of a composite panel comprising: 
 A. simultaneously roll-forming a metal sheet and a waterproof, membranous layer to provide a sheet laminate comprising a metal layer having a layer of waterproof, membranous material on its top surface,    B. roll-forming a second metal sheet, optionally applying a decorative coating to the bottom surface of the second metal sheet;    C. arranging the first and second metal sheet with the top surface of said second sheet opposing the bottom surface of said first sheet; and    D. providing therebetween, a volume of insulating material.    
   
   
       9 . A method as claimed in  claim 8  characterised in that steps A and B are carried out simultaneously.  
   
   
       10 . A method as claimed in  claim 8  characterised in that step D involves injecting a foaming polymeric insulating material between the arranged metal sheets and allowing the composite to cure.  
   
   
       11 . A method as claimed in  claim 8  characterised in that step D involves spraying a chemical bonding agent to the top surface of said decking and the bottom surface of said top sheet and providing therebetween an insulating material.  
   
   
       12 . A method as claimed in  claim 8  characterised by the further step of applying pressure to the composite as it cures.  
   
   
       13 . A method as claimed in  claim 12  wherein the step of applying pressure involves the use of a vacuum table, a platen press, a bag press or a nip rolling apparatus.