Roofing composite panel and method of installation thereof

Abstract

A composite panel, has: an insulating subpanel having a bottom face to be secured to a substrate and a top face opposed to the bottom face, the top face and the bottom face delimited by interconnected edges of the insulating subpanel; a polymer membrane adhered to a portion of the top face, the polymer membrane including a flap, the flap extending from a membrane edge of the membrane to a junction between the flap and a remainder of the polymer membrane, the junction being recessed inwardly from an edge of the interconnected edges of the insulating subpanel such that a portion of the top face of the insulating subpanel is free from attachment to the polymer membrane, a length of the flap extending from the membrane edge to the junction being greater than a distance between the edge of the interconnected edges and the junction.

1 . A composite panel, comprising:
 an insulating subpanel having a bottom face to be secured to a substrate and a top face opposed to the bottom face, the top face and the bottom face delimited by interconnected edges of the insulating subpanel;   a polymer membrane adhered to a portion of the top face, the polymer membrane including a flap, the flap extending from a membrane edge of the membrane to a junction between the flap and a remainder of the polymer membrane, the junction being recessed inwardly from an edge of the interconnected edges of the insulating subpanel such that a portion of the top face of the insulating subpanel is free from attachment to the polymer membrane, a length of the flap extending from the membrane edge to the junction being greater than a distance between the edge of the interconnected edges and the junction.   
     
     
         2 . The composite panel of  claim 1 , wherein the length is about twice the distance between the edge of the interconnected edges and the junction. 
     
     
         3 . The composite panel of  claim 1 , comprising an adhesive applied to the flap. 
     
     
         4 . The composite panel of  claim 3 , comprising a release membrane in contact and overlapping the adhesive, the release membrane removable from the flap. 
     
     
         5 . The composite panel of  claim 4 , wherein the flap includes a proximal section and a distal section, the proximal section located between the distal section and an intersection between the flap and the remainder of the polymer membrane, the adhesive located on the proximal section, the distal section being free of the adhesive. 
     
     
         6 . The composite panel of  claim 1 , wherein a width of the flap is about 6 inches. 
     
     
         7 . The composite panel of  claim 1 , wherein the insulating panel is made of one or more of polyisocyanurate, polystyrene, fiber, stone wool, and rock wool. 
     
     
         8 . The composite panel of  claim 1 , wherein the insulating panel has a density of from 80 to 140 lb/ft 2 , inclusively. 
     
     
         9 . The composite panel of  claim 1 , wherein the polymer membrane is made of one or more of thermoplastic polyolefin and polyvinyl chloride. 
     
     
         10 . The composite panel of  claim 1 , comprising fastener-receiving locations for receiving fasteners through the insulating subpanel, the fastener-receiving locations located within the portion of the top face free from attachment to the polymer membrane. 
     
     
         11 . The composite panel of  claim 10 , wherein the fastener-receiving locations are defined by fastening apertures, reinforcing inserts received within the fastening apertures. 
     
     
         12 . An assembly of composite panels for a roof, comprising:
 a first composite panel and a second composite panel located adjacent the second composite panel, the first composite panel having:
 an insulating subpanel having a bottom face to be secured to a substrate and a top face opposed to the bottom face, the top face and the bottom face delimited by interconnected edges of the insulating subpanel; 
 a polymer membrane adhered to a portion of the top face, the polymer membrane including a flap, the flap ending at a membrane edge located outwardly of the insulating subpanel and overlapping a joint between the first composite panel and the second composite panel. 
   
     
     
         13 . The assembly of  claim 12 , wherein the flap overlaps the joint, a first row of fasteners extending through the insulating subpanel, and a second row of fasteners extending through a second insulating subpanel of the second composite panel. 
     
     
         14 . The assembly of  claim 12 , wherein the flap is fused to a second polymer membrane of the second composite panel. 
     
     
         15 . The assembly of  claim 12 , wherein the insulating panel is made of one or more of polyisocyanurate, polystyrene, fiber, stone wool, and rock wool. 
     
     
         16 . The assembly of  claim 12 , wherein the flap is secured to the insulating subpanel and to the second composite panel via an adhesive. 
     
     
         17 . A method of installing a composite panel on a roof, the composite panel including an insulating subpanel and a polymer membrane adhered to the insulating subpanel, the method comprising:
 disposing the composite panel on a substrate of the roof;   lifting a flap of the polymer membrane thereby exposing an edge portion of the insulating subpanel and fastening the insulating subpanel to the substrate; and   adhering the flap to both of the edge portion of the insulating subpanel and to an adjacent composite panel.   
     
     
         18 . The method of  claim 17 , wherein the adhering of the flap includes covering both of a joint between the insulating subpanel and the adjacent composite panel and a row of fasteners extending through the adjacent composite panel. 
     
     
         19 . The method of  claim 17 , wherein the adhering of the flap includes peeling of a release membrane disposed on the flap to expose an adhesive and adhering the flap using the adhesive. 
     
     
         20 . The method of  claim 19 , wherein the adhering of the flap further includes fusing a distal section of the flap to a second polymer membrane of the adjacent composite panel.