Intermediate composite panel for roofing and walls

Abstract

A composite intermediate panel comprises a structural layer providing the structural integrity of the composite intermediate panel. Pressure-sensitive adhesive layers are on opposite main surfaces of the structural panel, the pressure-sensitive adhesive layers applied in plant. A backing sheet layer is provided for each adhesive layer, the backing sheet layer adhered to the pressure-sensitive adhesive layer, and being peelable off the pressure-sensitive adhesive layer to expose the pressure-sensitive layer. Attachment units of rigid material are on one of the main surfaces of the building panel, the attachment units being positioned at a location where mechanical fasteners secure the building panel to a structure.

1 . A composite intermediate panel comprising:
 a structural layer providing the structural integrity of the composite intermediate panel;   pressure-sensitive adhesive layers on opposite main surfaces of the structural panel, the pressure-sensitive adhesive layers applied in plant;   a backing sheet layer for each adhesive layer, the backing sheet layer adhered to the pressure-sensitive adhesive layer, and being peelable off the pressure-sensitive adhesive layer to expose the pressure-sensitive layer; and   at least one attachment unit of rigid material on at least one of the main surfaces of the building panel, the at least one attachment unit being positioned at a location where mechanical fasteners secure the building panel to a structure.   
     
     
         2 . The composite intermediate panel according to  claim 1 , wherein the at least one attachment unit is between the pressure-sensitive adhesive layer and the backing sheet layer. 
     
     
         3 . The composite intermediate panel according to  claim 2 , further comprising a visual indicator on the backing sheet layer to indicate a position of the at least one attachment unit. 
     
     
         4 . The composite intermediate panel according to  claim 1 , wherein the at least one attachment unit is a longitudinal attachment strip. 
     
     
         5 . The composite intermediate panel according to  claim 4 , wherein the longitudinal attachment strip has a length ranging between 16″ and 20″, on a width of the composite intermediate panel. 
     
     
         6 . The composite intermediate panel according to  claim 5 , wherein the width of the composite intermediate panel is about 48″. 
     
     
         7 . The composite intermediate panel according to  claim 1 , wherein the at least one attachment unit is made of metal. 
     
     
         8 . The composite intermediate panel according to  claim 1 , further comprising rabbets at edges of the structural layer for side by side assembly of two of the composite intermediate panel. 
     
     
         9 . The composite intermediate panel according to  claim 1 , wherein the pressure-sensitive adhesive comprise at least one of a bitumen adhesive, polyurethane resin, urethane and polyurethane-based adhesive, asphaltic urethane, solvent-based or solvent-free adhesives, acrylic adhesive, chlorinated asphaltic composite, synthetic-polymer adhesives, polyvinyl acetate, polyvinyl alcohol, polyester adhesives, neoprene, butyl rubber, thermoplastic elastomers. 
     
     
         10 . The composite intermediate panel according to  claim 1 , wherein the structural layer has a thickness ranging between 0.25″ and 8.0″ inclusively. 
     
     
         11 . The composite intermediate panel according to  claim 1 , wherein each said pressure-sensitive adhesive layer has between 0.04-0.20 lb/ft 2  inclusively of adhesive. 
     
     
         12 . The composite intermediate panel according to  claim 1 , wherein the backing sheet layer is made with at least one of plastic, thermo-fusible plastic, paper, plasticized paper, Kraft paper, organic felt, and fiberglass. 
     
     
         13 . The composite intermediate panel according to  claim 1 , wherein the at least one attachment unit has a hole to receive a fastener. 
     
     
         14 . The composite intermediate panel according to  claim 1 , further comprising a functional layer between the structural layer and one of the pressure-sensitive adhesive layers. 
     
     
         15 . The composite intermediate panel according to  claim 14 , wherein the functional layer is an air barrier made of one of woven alkenes bound by polymers, spun polyolefin bound by polymers, and sheeted polyethylene. 
     
     
         16 . The composite intermediate panel according to  claim 14 , wherein the functional layer is a vapor barrier made of at least one of woven polyethylene, woven polypropylene, mixtures woven polyethylene and woven polypropylene, kraft paper with polyethylene, paint, polymers, adhesives, sealants, and concrete. 
     
     
         17 . The composite intermediate panel according to  claim 14 , wherein the functional layer is an insulating barrier made at least one of expanded polystyrene, extruded polystyrene, polyisocyanurate, expanded resins, mineral fibers and glass fibers.