Integrated roofing systems

Abstract

In one embodiment, this invention relates to integrated roofing system panels that comprise insulation layer, and one or more modified bitumen layers, optionally structurally stable layers, and optionally perforated aluminum-based layers that have a modified bitumen base, wherein the integrated system allows for ease of installation and labor savings while providing properties such as water resistance, durability, and fire resistance, among other things.

Description

[0001] PCT Application BH Ref.: 092457.000613 TITLE

[0002] Integrated Roofing Systems

[0003] CROSS REFERENCE TO RELATED APPLICATIONS

[0004] The present application hereby claims the benefit of the provisional patent application of the same title, U.S. Application No. 63 / 739,152, filed December 27, 2024, the disclosure of which is herein incorporated by reference in its entirety.

[0005] FIELD OF INVENTION

[0006] In one embodiment, this invention relates to integrated roofing system panels that comprise insulation layer, and one or more modified bitumen layers, optionally structurally stable layers, and optionally perforated aluminum-based layers that have a modified bitumen base, wherein the integrated system allows for ease of installation and labor savings while providing properties such as water resistance, durability, and fire resistance, among other things.

[0007] BACKGROUND

[0008] Building roofs can experience water leaks and water collection or demonstrate low energy efficiency. Water leaking inside the building can create safety hazard for workers and damage to the structure and ponding water on the roof can lead to structural damage and bugs or mold infestation. Clearly, wasted energy is a loss to the property owner. To address these issues, a membrane roof can be installed. A membrane roof is a flexible or semi-flexible roof covering material that primarily waterproofs a roof system. It can be made of a single material or several laminated materials together. While membrane materials can sometimes be used on residential roofing, they are primarily used for commercial or industrial buildings with flat- or low-slope roofs. Even flat roofs are not truly flat but have a slight pitch to facilitate water drainage. At the same time, it is imperative that the roofs provide a water-resistive barrier property. For example, rainwater or melting snow might not immediately flow off the top, like on roofs with steeper pitches. Selecting a suitable roof membrane is especially critical for commercial building owners with flat- or low-slope roofs.

[0009] Membrane roofs primarily include those made from the built-up roofing (BUR); ethylene propylene diene monomer (EPDM); polyvinyl chloride (PVC); thermoplastic polyolefin (TPO); and modified bitumen (MB). Other materials such as styrene-butadiene-styrene (SBS), atactic polypropylene (APP), and ketone ethylene ester (KEE) can also be sued to a lesser extent for preparing membrane roofs.

[0010] 092457.000613\4914-5120-8069.1PCT Application BH Ref.: 092457.000613

[0011] Each roof membrane type has its advantages, and which one is better depends on the geography, the building’s usage, and needs.

[0012] A BUR-membrane roof is one of the oldest commercial roofing but is still used today. Felt or fabric layers— called plies— are “built-up” on top of the roof and infused with bitumen. The plies are alternated with other asphalt-based materials like tar / bitumen. BUR roofs provide longer life, good fire resistance, durability, and waterproofing. Newer BUR roofs are sometimes called modified bitumen membranes and include additional materials to make them stronger.

[0013] EPDM roofing material, sometimes called a rubber roof membrane, is the second common type of membrane. As a single-ply membrane roofing, EPDM can be applied to fully -adhered, ballasted, and loose-laid protected roofing systems. For the fully-adhered systems, the EPDM membrane is coated in an adhesive and then rolled into place and broomed down, and for the ballasted and loose-laid systems, it is loose-laid on the roof. Some advantages to EPDM roofs include wear, fatigue, and impact resistance. The membrane is durable and waterproof.

[0014] PVC roof membrane is a thermoplastic material that softens when heated and more rigid when cooled. The membrane is commonly placed down in overlapping sheets. The seams are hot-air welded to ensure a watertight seal. PVC roofing is ideal for food-production facilities and restaurants, as the material are highly resistant to chemicals, fire, and grease.

[0015] The thermoplastic olefin (TPO) roofing material is similar to PVC. The membrane is adhered to the roof using a bonding adhesive for fully-adhered systems or with plates and fasteners for a mechanically-fastened roof system. These roofing membranes are an excellent choice for commercial buildings and provide durability against various temperatures and weather, are energy efficient, and long -lasting. Like BUR, modified bitumen roofing (MB) is a commercial flat roofing material constructed in layers. The MB roofs uses heavy fraction of petroleum-based substance between the plies, providing a rubberized appearance and properties. Benefits of an MB roof include its ability to withstand regular foot traffic, ease of installation without the use of heat, durability, and reflective property that can provide energy savings for the building.

[0016] Many factors need to be considered to determine the best roof membrane, for example, the roof s pitch, the business being conducted inside, the existing roof material, the kind of roofing system, the roof s condition are just a few considerations needed. In addition to the above, however, it is desired to have the ability to simplify installation with a combination of desired characteristics such as insulation, water resistivity, mechanical integrity, toughness or impact resistance, resistance to wear or durability, sound absorption, fire resistance, antifouling properties, and the like.

[0017] To address the above issues, in one embodiment, this invention relates to combining the modified bitumen technology with insulation to develop a high performing integrated roofing system that retainsPCT Application BH Ref.: 092457.000613

[0018] the desired properties, can be sealed faster, and that which saves significantly on labor. In some embodiments, the present invention would allow for saving on installation by not requiring installing of densdeck® or securerock®, and saving on adhesive, labor, and other accessories. The integrated roofing system of the present invention has a wider application temperature range, fast turnaround time, and best in class durability, sound absorption, and fire resistance, from combustible to non-combustible, wind-uplift resistance, puncture resistance and hail resistance.

[0019] SUMMARY OF INVENTION

[0020] In one embodiment, the integrated roofing system of the present invention comprises flaps for faster seal treatment. The embodiment relates to heat treating the flaps in the field to form the seam and save on labor.

[0021] In another embodiment, this invention relates to a first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:

[0022] (i) a first insulation layer having an outer surface and an inner surface;

[0023] (ii) a first perforated waterproofing membrane (PWPM) layer having an outer surface and an inner surface, wherein the inner surface of the first PWPM layer or the side having the perforated aluminum sheet, is secured to the outer surface of the first insulation layer, optionally through an adhesive layer,

[0024] wherein the first PWPM layer optionally exceeds the dimensions of the first insulation layer from at least one of its edges to form a portion of an optional extension flap,

[0025] wherein the extension flap of the first PWPM layer further comprises a removably attached release-liner attached to the PWPM layer’s inner surface, and

[0026] wherein the first PWPM layer comprises a modified bitumen layer and a perforated aluminum foil;

[0027] and

[0028] (iii) a first modified bitumen (MB) layer having an outer surface and an inner surface, wherein the inner surface of the first MB layer is secured to the outer surface of the first PWPM layer, optionally through an adhesive layer,

[0029] wherein the first MB layer optionally exceeds the dimensions of the first insulation layer from at least one of its edges to be a portion of the optional extension flap.PCT Application BH Ref.: 092457.000613

[0030] In yet another embodiment, this invention relates to a first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:

[0031] (i) a first insulation layer having an outer surface and an inner surface;

[0032] and

[0033] (ii) a first modified bitumen (MB) layer having an outer surface and an inner surface, wherein the inner surface of the first MB layer is contactably attached to the outer surface of the first insulation layer, without any fastening mechanism, optionally through an adhesive layer, thermally, or a combination thereof,

[0034] wherein the first MB layer optionally exceeds the dimensions of the first insulation layer from at least one of its edges to be a portion of the extension flap.

[0035] In one embodiment, this invention relates to a first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:

[0036] (i) a first insulation layer having an outer surface and an inner surface;

[0037] and

[0038] (ii) a first modified bitumen (MB) layer having an outer surface and an inner surface, wherein the inner surface of the first MB layer is contactably attached to the outer surface of the first insulation layer without any fastening mechanism, through a plurality of fasteners, through an adhesive layer, thermally, or a combination thereof, and wherein the plurality of fasteners penetrates the first MB layer and the first insulation layer and into the roof deck; wherein the first insulation layer exceeds the dimensions of the first MB layer from at least one of its edges to be a portion of an extension flap.

[0039] In another embodiment, this invention relates to the first IRS panel as recited above, wherein at least one fastener of the plurality of fasteners is a metal fastener.

[0040] In yet another embodiment, this invention relates to a first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:

[0041] (i) a first insulation layer having an outer surface and an inner surface;PCT Application BH Ref.: 092457.000613

[0042] and

[0043] (ii) a first modified bitumen (MB) layer having an outer surface and an inner surface, wherein the inner surface of the first MB layer is contactably attached to the outer surface of the first insulation layer without any fastening mechanism, through a plurality of fasteners, through an adhesive layer, or both, and wherein the plurality of fasteners penetrates the first insulation layer and not the first MB layer and into the roof deck;

[0044] wherein the first insulation layer exceeds the dimensions of the first MB layer from at least one of its edges to be a portion of an extension flap.

[0045] In one embodiment, this invention relates to a first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:

[0046] (i) a first insulation layer having an outer surface and an inner surface;

[0047] and

[0048] (ii) a first modified bitumen (MB) layer having an outer surface and an inner surface, wherein the inner surface of the first MB layer is contactably attached to the outer surface of the first insulation layer through a plurality of fasteners, through an adhesive layer, or both, and wherein at least one of the fasteners from the plurality of fasteners penetrates the first MB layer, the first insulation layer, and the roof deck;

[0049] wherein the first insulation layer exceeds the dimensions of the first MB layer from at least one of its edges to be a portion of an extension flap.

[0050] In another embodiment, this invention relates to the first IRS panel as recited above, wherein at least one fastener of the plurality of fasteners is a metal fastener.

[0051] In yet another embodiment, this invention relates to a panel assembly comprising at least two panels, a first IRS panel and a second IRS panel for construction purposes, each panel comprising the following layers:

[0052] (i) a first insulation layer having an outer surface and an inner surface;

[0053] and

[0054] (ii) a first modified bitumen (MB) layer having an outer surface and an inner surface,PCT Application BH Ref.: 092457.000613

[0055] wherein the inner surface of the first MB layer is contactably attached to the outer surface of the first insulation layer without any fastening mechanism, through a plurality of fasteners, through an adhesive layer, thermally, or a combination thereof, and wherein at least one of the fasteners from the plurality of fasteners penetrates the first MB layer, the first insulation layer, and the roof deck;

[0056] wherein the first insulation layer optionally exceeds the dimensions of the first MB layer from at least one of its edges to be a portion of an extension flap;

[0057] wherein said two IRS panels are contactably juxtaposed to or contactably attached to each other, wherein a seam layer is contactably attached in between the modified bitumen layers of the two panels placed side-by-side, wherein the width of the seam layer ranges from 0% to 25% of the width of the MB layer, wherein the 0% corresponds to the embodiment wherein the first MB layer and the corresponding first insulation layer of the first IRS panel are flush with each other, and wherein the first MB layer and the corresponding first insulation layer of the second IRS panel are flush with each other, and wherein the two panels are contactably attached or juxtaposed to each other.

[0058] In one embodiment, this invention relates to the panel assembly as recited above, wherein at least one fastener of the plurality of fasteners is a metal fastener.

[0059] In another embodiment, this invention relates to a panel assembly comprising at least two panels, a first IRS panel and a second IRS panel for construction purposes, each panel comprising the following layers:

[0060] (i) a first insulation layer having an outer surface and an inner surface;

[0061] (ii) a first modified bitumen (MB) layer (or the base layer) having an outer surface and an inner surface,

[0062] wherein the inner surface of the first MB layer is contactably attached to the outer surface of the first insulation layer without any fastening mechanism, through a plurality of fasteners, through an adhesive layer, thermally, or a combination thereof, and wherein at least one of the fasteners from the plurality of fasteners penetrates the first MB layer, the first insulation layer, and the roof deck;

[0063] wherein the first insulation layer optionally exceeds the dimensions of the first MB layer from at least one of its edges to be a portion of an extension flap;PCT Application BH Ref.: 092457.000613

[0064] wherein said first and second IRS panels are contactably juxtaposed to or contactably attached to each other,

[0065] wherein a seam layer is contactably attached in between the modified bitumen layers of the two panels placed side-by-side, wherein the width of the seam layer ranges from 0% to 25% of the width of the MB layer, wherein the 0% corresponds to the embodiment wherein the first MB layer and the corresponding first insulation layer of the first IRS panel are flush with each other, and wherein the first MB layer and the corresponding first insulation layer of the second IRS panel are flush with each other, and wherein the two panels are contactably attached or juxtaposed to each other; and

[0066] (iii) a second modified bitumen layer (MB2) layer, contactably attached to the MB layers, with or without the seam layer,

[0067] wherein the MB2 layer (or the cap layer) is placed contactably positioned or attached on top of the MB layer and on the side of the MB layer that is opposite to the side where the first insulation layer is located, and

[0068] wherein the MB2 layer is amenable to adhesion and softening thru a thermal treatment.

[0069] In another embodiment, this invention relates to the panel assembly as recited above, wherein at least one fastener of the plurality of fasteners is a metal fastener.

[0070] In yet another embodiment, this invention relates to a first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:

[0071] (i) a first insulation layer having an outer surface and an inner surface;

[0072] and

[0073] (ii) a first modified bitumen (MB) layer having an outer surface and an inner surface, wherein the inner surface of the first MB layer is contactably attached to the outer surface of the first insulation layer, optionally through an adhesive layer,

[0074] wherein the first MB layer optionally exceeds the dimensions of the first insulation layer from at least one of its edges to be a portion of the extension flap, and

[0075] wherein the first insulation layer optionally exceeds the dimensions of the first MB layer from at least one of its edges to be a portion of a second extension flap.PCT Application BH Ref.: 092457.000613

[0076] In one embodiment, this invention relates to the first IRS panel as recited above, wherein the MB layer is contactably attached to the first insulation layer without any fastening mechanism, through an adhesive, through a plurality of fasteners, thermally, or a combination thereof.

[0077] In another embodiment, this invention relates to the first IRS panels as recited above, wherein at least one fastener of the plurality of fasteners is a metal fastener.

[0078] In yet another embodiment, this invention relates to a first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:

[0079] (i) a first insulation layer having an outer surface and an inner surface;

[0080] and

[0081] (ii) a first modified bitumen (MB) layer having an outer surface and an inner surface, wherein the inner surface of the first MB layer is contactably attached to the outer surface of the first insulation layer, optionally through an adhesive layer, a plurality of fasteners, thermally, or a combination thereof

[0082] In one embodiment, this invention relates to the first IRS panel as recited above, wherein the MB layer is contactably attached to the first insulation layer without any fastening mechanism, through an adhesive, through a plurality of fasteners, or a combination thereof.

[0083] In another embodiment, this invention relates to the first IRS panel as recited above, wherein at least one fastener of the plurality of fasteners is a metal fastener.

[0084] In yet another embodiment, this invention relates to a first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:

[0085] (i) a first insulation layer having an outer surface and an inner surface;

[0086] and

[0087] (ii) a first structurally stable (SS) panel having an outer surface and an inner surface,PCT Application BH Ref.: 092457.000613

[0088] wherein the inner surface of the first MB layer is contactably attached to the outer surface of the first insulation layer, without any fastening mechanism, optionally through an adhesive layer, a plurality of fasteners, or a combination thereof.

[0089] In one embodiment, this invention relates to the first IRS panel as recited above, wherein the SS panel comprises gypsum.

[0090] In another embodiment, this invention relates to the first IRS panels as recited above, wherein at least one fastener of the plurality of fasteners is a metal fastener.

[0091] In yet another embodiment, this invention relates to a first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:

[0092] (i) a first insulation layer having an outer surface and an inner surface;

[0093] (ii) a first structurally stable (SS) panel having an outer surface and an inner surface, wherein the inner surface of the first SS layer is contactably attached to the outer surface of the first insulation layer, without any fastening mechanism, optionally through an adhesive layer, a plurality of fasteners, or a combination thereof; and

[0094] (iii) a first modified bitumen (MB) layer having an outer surface and an inner surface, wherein the inner surface of the first MB layer (base sheet) is contactably attached to the outer surface of the first SS layer, optionally through an adhesive layer, a plurality of fasteners, thermally, or a combination thereof

[0095] In one embodiment, this invention relates to the first IRS panel as recited above, wherein the SS panel comprises gypsum.

[0096] In another embodiment, this invention relates to the first IRS panels as recited above, wherein at least one fastener of the plurality of fasteners is a metal fastener.

[0097] In yet another embodiment, this invention relates to a first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:

[0098] (i) a first insulation layer having an outer surface and an inner surface;PCT Application BH Ref.: 092457.000613

[0099] (ii) a first structurally stable (SS) panel having an outer surface and an inner surface, wherein the inner surface of the first SS layer is contactably attached to the outer surface of the first insulation layer, without any fastening mechanism, optionally through an adhesive layer, a plurality of fasteners, or a combination thereof;

[0100] (iii) a first modified bitumen (MB) layer having an outer surface and an inner surface, wherein the inner surface of the first MB layer (base sheet) is contactably attached to the outer surface of the first SS layer, optionally through an adhesive layer, a plurality of fasteners, thermally, or a combination thereof; and

[0101] (iv) a second modified bitumen (MB2) layer (cap sheet) having an outer surface and an inner surface,

[0102] wherein the inner surface of the second MB layer is contactably attached to the inner surface of the first MB layer, without any fastening mechanism, optionally through an adhesive layer, a plurality of fasteners, or a combination thereof; and

[0103] In one embodiment, this invention relates to the first IRS panel as recited above, wherein the SS panel comprises gypsum.

[0104] In another embodiment, this invention relates to the first IRS panels as recited above, wherein at least one fastener of the plurality of fasteners is a metal fastener.

[0105] In yet another embodiment, this invention relates to a first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:

[0106] (i) a first insulation layer having an outer surface and an inner surface;

[0107] (ii) a first structurally stable (SS) panel having an outer surface and an inner surface, wherein the inner surface of the first SS layer is contactably attached to the outer surface of the first insulation layer, without any fastening mechanism, optionally through an adhesive layer, a plurality of fasteners, or a combination thereof;

[0108] (iii) a first modified bitumen (MB) layer having an outer surface and an inner surface, wherein the inner surface of the first MB layer (base sheet) is contactably attached to the outer surface of the first SS layer, optionally through an adhesive layer, a plurality of fasteners, thermally, or a combination thereof; andPCT Application BH Ref.: 092457.000613

[0109] (iv) a second modified bitumen (MB2) layer (cap sheet) having an outer surface and an inner surface,

[0110] wherein the inner surface of the second MB layer is contactably attached to the inner surface of the first MB layer, without any fastening mechanism, optionally through an adhesive layer, a plurality of fasteners, or a combination thereof; and

[0111] wherein the first MB layer extends at least on one of its edges beyond the first SS layer to create a first extension flap, wherein the extension flap is from about 0% to about 20% of the width of the first SS layer, and / or

[0112] wherein the second MBs layer extends at least on one of its edge beyond the first SS layer to create a second extension flap, wherein the second extension flap is from about 0% to about 20% of the width of the first SS layer,

[0113] wherein the width of the first extension flap is the same or different from the width of the second extension flap.

[0114] In one embodiment, this invention relates to the first IRS panel as recited above, wherein the SS panel comprises gypsum.

[0115] In another embodiment, this invention relates to the first IRS panels as recited above, wherein at least one fastener of the plurality of fasteners is a metal fastener.

[0116] BRIEF DESCRIPTION OF DRAWINGS FIG. 1 shows a schematic of an integrated roofing system panel comprising an insulation layer, a perforated aluminum sheet with a modified bitumen backing, and a modified bitumen cap layer.

[0117] FIG. 2 shows a schematic of an integrated roofing system panel comprising an insulation layer and a modified bitumen layer, where the insulation layer extends outside of the width of the MB layer. FIG. 3 shows a schematic of an integrated roofing system panel comprising an insulation layer and a modified bitumen layer, where both layers are fastened to the roof deck using metal fasteners.

[0118] FIG. 4 shows a schematic of an integrated roofing system panel comprising an insulation layer and a modified bitumen layer, where the insulation layer is fastened to the roof deck using metal fasteners.PCT Application BH Ref.: 092457.000613

[0119] FIG. 5 shows a schematic of an assembly of integrated roofing system panels comprising an insulation layer and a modified bitumen layer, where both layers are fastened to the roof deck using metal fasteners and wherein a seam layer is placed in between the modified bitumen layers of the two panels.

[0120] FIG. 6 shows a schematic of an assembly of integrated roofing system panels comprising an insulation layer and a modified bitumen layer base and a modified bitumen layer cap wherein all three layers are fastened to the roof deck using metal fasteners and wherein a seam layer is placed in between the modified bitumen layers of the two panels.

[0121] FIG. 7 shows a schematic of an integrated roofing system panel comprising an insulation layer and a modified bitumen layer, where the MB layer extends outside of the width of the insulation layer. FIG. 8 shows a schematic of an integrated roofing system panel comprising an insulation layer and a modified bitumen layer.

[0122] FIG. 9 shows a schematic of an integrated roofing system panel comprising an insulation layer and a structurally-stable layer comprising gypsum.

[0123] FIG. 10 shows a schematic of an integrated roofing system panel comprising an insulation layer, a structurally-stable layer comprising gypsum, and a modified bitumen layer on the SS layer.

[0124] FIG. 11 shows a schematic of an integrated roofing system panel comprising an insulation layer, a structurally-stable layer comprising gypsum, and a modified bitumen layer as a base layer on the SS layer, and a modified bitumen layer as the cap layer on the base layer.

[0125] FIG. 12 shows a schematic of an integrated roofing system panel comprising an insulation layer, a structurally-stable layer comprising gypsum, and a modified bitumen layer as a base layer on the SS layer, and a modified bitumen layer as the cap layer on the base layer, wherein the cap layer extends beyond the width of the SS layer.

[0126] FIG. 13 shows a schematic of an integrated roofing system panel comprising an insulation layer, a structurally-stable layer comprising gypsum, and a modified bitumen layer as a base layer on the SS layer, and a modified bitumen layer as the cap layer on the base layer, wherein the cap layer and the base layer independently extend beyond the width of the SS layer.

[0127] DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0128] Before the present compositions, articles, devices, and / or methods are disclosed and described, it is to be understood that the aspects described below are not limited to specific methods as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describingPCT Application BH Ref.: 092457.000613

[0129] particular aspects only and is not intended to be limiting. As used in the specification and in the claims, the term “comprising” may include the embodiments “consisting of’ and “consisting essentially of.” Disclosed are materials, compositions, and components that can be used for, can be used in conjunction with, can be used in preparation for, or are products of the disclosed method and compositions. These and other materials are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, and the like of these materials are disclosed that while specific reference of each various individual and collective combinations and permutation of these compounds cannot be explicitly disclosed, each is specifically contemplated and described herein. Thus, if a class of adhesives A, B, and C are disclosed as well as a class of additives D, E, and F and an example of a combination A-D is disclosed, then even if each is not individually recited, each is individually and collectively contemplated. Thus, in this example, each of the combinations A-E, A-F, B-D, B-E, B-F, C-D, C-E, and C-F are specifically contemplated and should be considered disclosed from disclosure of A, B, and C; D, E, and F; and the example combination A-D. Likewise, any subset or combination of these is also specifically contemplated and disclosed. Thus, for example, the sub-group of A-E, B-F, and C-E are specifically contemplated and should be considered disclosed from disclosure of A, B, and C; D, E, and F; and the example combination A-D. This concept applies to all aspects of this disclosure including, but not limited to, compositions, and steps in methods of making and using the disclosed compositions. Thus, if there are a variety of additional steps that can be performed it is understood that each of these additional steps can be performed with any specific embodiment or combination of embodiments of the disclosed methods, and that each such combination is specifically contemplated and should be considered disclosed.

[0130] Unless expressly stated otherwise, it is not intended that any method outlined herein be construed as requiring that its steps be performed in a particular order. Accordingly, where a method claim does not expressly recite an order to be followed by its steps, or where neither the claims nor the descriptions specifically state that the steps are to be limited to a precise sequence, it should not be inferred that a specific order is intended or required. This holds for any possible non-express basis for interpretation, including, but not limited to: logical flow or arrangement of steps; interpretations derived from the grammatical organization, syntax, or punctuation; and the quantity or variety of embodiments detailed in the specification. The description of the invention should not be read as mandating a fixed sequence of steps, unless such a requirement is articulated explicitly.

[0131] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. In case of conflict, the present specification, including definitions, will control.

[0132] Except where expressly noted, trademarks are shown in upper case.PCT Application BH Ref.: 092457.000613

[0133] Unless stated otherwise, all percentages, parts, ratios, a., are by weight. Ranges can be expressed herein as from “about” one particular value, and / or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. It is also understood that there are a number of values disclosed herein, and that each value is also herein disclosed as “about” that particular value in addition to the value itself. For example, if the value “10” is disclosed, then “about 10” is also disclosed. It is also understood that each unit between two particular units are also disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

[0134] Unless stated otherwise, pressures expressed in psi units would be gauge, and pressures expressed in kPa units would be absolute. Pressure differences, however, are expressed as absolute (for example, pressure 1 is 25 psi higher than pressure 2).

[0135] When an amount, concentration, or other value or parameter is given as a range, or a list of upper and lower values, this is to be understood as specifically disclosing all ranges formed from any pair of any upper and lower range limits, regardless of whether ranges are separately disclosed. Where a range of numerical values is recited herein, unless otherwise stated, the range is intended to include the endpoints thereof, and all integers and fractions within the range. It is not intended that the scope of the present disclosure be limited to the specific values recited when defining a range.

[0136] When the term “about” is used, it is used to mean a certain effect or result can be obtained within a certain tolerance, and the skilled person knows how to obtain the tolerance. When the term "about" is used in describing a value or an endpoint of a range, the disclosure should be understood to include the specific value or endpoint referred to.

[0137] As used herein, the terms "comprises," "comprising," "includes," "including," "has," "having" or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but can include other elements not expressly listed or inherent to such process, method, article, or apparatus.

[0138] The transitional phrase "consisting of' excludes any element, step, or ingredient not specified in the claim, closing the claim to the inclusion of materials other than those recited except for impurities ordinarily associated therewith. When the phrase "consists of' appears in a clause of the body of a claim, rather than immediately following the preamble, it limits only the element set forth in that clause; other elements are not excluded from the claim as a whole.PCT Application BH Ref.: 092457.000613

[0139] The transitional phrase "consisting essentially of' limits the scope of a claim to the specified materials or steps and those that do not materially affect the basic and novel characteristic(s) of the claimed invention. A “consisting essentially of’ claim occupies a middle ground between closed claims that are written in a “consisting of’ format and fully open claims that are drafted in a “comprising” format. Optional additives as defined herein, at a level that is appropriate for such additives, and minor impurities are not excluded from a composition by the term “consisting essentially of.”

[0140] Further, unless expressly stated to the contrary, "or" and “and / or” refers to an inclusive and not to an exclusive. For example, a condition A or B, or A and / or B, is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0141] The use of "a" or "an" to describe the various elements and components herein is merely for convenience and to give a general sense of the disclosure. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise. As used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

[0142] The term “predominant portion” or “predominantly,” as used herein, unless otherwise defined herein, means greater than 50% of the referenced material. If not specified, the percent is on a molar basis when reference is made to a molecule (such as hydrogen and ethylene), and otherwise is on a weight basis (such as for additive content).

[0143] The term “substantial portion” or “substantially,” as used herein, unless otherwise defined, means all or almost all or the vast majority, as would be understood by the person of ordinary skill in the context used. It is intended to take into account some reasonable variance from 100% that would ordinarily occur in industrial-scale or commercial-scale situations.

[0144] All parts, percentages and ratios used herein are expressed by weight unless otherwise specified. In this specification and in the claims which follow, reference will be made to a number of terms which shall be defined herein.

[0145] “Optional” or “optionally” means that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where the event or circumstance occurs and instances where it does not.

[0146] While aspects of the present invention can be described and claimed in a particular statutory class, such as the system statutory class, this is for convenience only and one of skill in the art will understand that each aspect of the present invention can be described and claimed in any statutory class. Unless otherwise expressly stated, it is in no way intended that any method or aspect set forth herein bePCT Application BH Ref.: 092457.000613

[0147] construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not specifically state in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including matters of logic with respect to arrangement of steps or operational flow, plain meaning derived from grammatical organization or punctuation, or the number or type of aspects described in the specification. Throughout this application, various publications are referenced. The disclosures of these publications in their entireties are hereby incorporated by reference into this application in order to more fully describe the state of the art to which they pertain. The references disclosed are also individually and specifically incorporated by reference herein for the material contained in them that is discussed in the sentence in which the reference is relied upon. Nothing herein is to be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention. Further, the dates of publication provided herein may be different from the actual publication dates, which can require independent confirmation. In the context of the present description, all publications, patent applications, patents and other references mentioned herein, if not otherwise indicated, are explicitly incorporated by reference herein in their entirety for all purposes as if fully set forth.

[0148] I. Illustrative Embodiments

[0149] The following describes exemplary embodiments of the present invention in the building construction context, which pertains to integrated roofing system (IRS) panels and panel assemblies suitable for use in the construction of residential and commercial buildings.

[0150] Embodiment 1

[0151] As shown in Fig. 1, this embodiment relates to first integrated roofing system (IRS) panel for construction purposes. It comprises the following layers:

[0152] (i) a first insulation layer having an outer surface and an inner surface;

[0153] (ii) a first perforated waterproofing membrane (PWPM) layer having an outer surface and an inner surface, wherein the inner surface of the first PWPM layer or the side having the perforated aluminum sheet, is secured to the outer surface of the first insulation layer, optionally through an adhesive layer, and

[0154] (iii)a first modified bitumen (MB) layer having an outer surface and an inner surface.

[0155] In one embodiment the first PWPM layer optionally exceeds the dimensions of the first insulation layer from at least one of its edges to form a portion of an optional extension flap. In another embodiment, the extension flap of the first PWPM layer further comprises a removably attached release -liner attached to the PWPM layer’s inner surface through an adhesive. In yet another embodiment, the first PWPMPCT Application BH Ref.: 092457.000613

[0156] layer comprises a modified bitumen layer and a perforated aluminum foil as described infra. In another embodiment, the inner surface of the first MB layer is secured to the outer surface of the first PWPM layer, optionally, through an adhesive layer. In yet another embodiment, even the first MB layer optionally exceeds the dimensions of the first insulation layer from at least one of its edges to be a portion of the optional extension flap. PWPM layer is also described infra as a weather-resistant barrier (WRB) layer infra. The insulation layer and the modified bitumen layer are also described in detail below.

[0157] Embodiment 2

[0158] As shown in Fig. 2, this embodiment pertains to a first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:

[0159] (i) a first insulation layer having an outer surface and an inner surface;

[0160] and

[0161] (ii) a first modified bitumen (MB) layer having an outer surface and an inner surface .

[0162] In a further embodiment, the inner surface of the first MB layer is contactably attached to the outer surface of the first insulation layer, without any fastening mechanism, optionally through an adhesive layer, thermally, or a combination thereof. In another embodiment, the first MB layer optionally exceeds the dimensions of the first insulation layer from at least one of its edges to be a portion of the extension flap.

[0163] Embodiment 3

[0164] As shown in Fig. 3, this invention relates to a first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:

[0165] (i) a first insulation layer having an outer surface and an inner surface;

[0166] and

[0167] (ii) a first modified bitumen (MB) layer having an outer surface and an inner surface .

[0168] In a further embodiment, the inner surface of the first MB layer can be contactably attached to the outer surface of the first insulation layer without any fastening mechanism, through a plurality of fasteners, through an adhesive layer, thermal application, or a combination thereof. In yet another embodiment, at least one fastener of the plurality of fasteners penetrates the first MB layer and the first insulation layer and into the roof deck. In a further embodiment, the first insulation layer exceeds the dimensions of the first MB layer from at least one of its edges to be a portion of an extension flap. In yet another embodiment, at least one fastener of the plurality of fasteners is a metal fastener. Metal fasteners herein can include nails, plates, screws, bolts, nuts, and other such hardware components.PCT Application BH Ref.: 092457.000613

[0169] Embodiment 4

[0170] As shown in Fig. 4, this invention relates to a first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:

[0171] (i) a first insulation layer having an outer surface and an inner surface;

[0172] and

[0173] (ii) a first modified bitumen (MB) layer having an outer surface and an inner surface .

[0174] In another embodiment, the inner surface of the first MB layer can be contactably attached to the outer surface of the first insulation layer without any fastening mechanism, through a plurality of fasteners, through an adhesive layer, thermal application, or a combination of these techniques. In another embodiment, the plurality of fasteners penetrates the first insulation layer and not the first MB layer and into the roof deck. In yet another embodiment, the first insulation layer exceeds the dimensions of the first MB layer from at least one of its edges to be a portion of an extension flap.

[0175] Embodiment 5

[0176] As shown in Fig. 5, in one embodiment, this invention relates to a first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:

[0177] (i) a first insulation layer having an outer surface and an inner surface;

[0178] and

[0179] (ii) a first modified bitumen (MB) layer having an outer surface and an inner surface .

[0180] In another embodiment, the inner surface of the first MB layer can be contactably attached to the outer surface of the first insulation layer through a plurality of fasteners, through an adhesive layer, through thermal application or through a combination of the aforementioned techniques. In yet another embodiment, at least one of the fasteners from the plurality of fasteners penetrates the first MB layer, the first insulation layer, and the roof deck. In another embodiment, the first insulation layer exceeds the dimensions of the first MB layer from at least one of its edges to be a portion of an extension flap. In another embodiment, at least one fastener of the plurality of fasteners is a metal fastener.

[0181] Embodiment 6

[0182] As shown in Fig. 6, in one embodiment, this invention relates to a panel assembly comprising at least two panels, a first IRS panel and a second IRS panel for construction purposes, each panel comprising the following layers:

[0183] (i) a first insulation layer having an outer surface and an inner surface;

[0184] andPCT Application BH Ref.: 092457.000613

[0185] (ii) a first modified bitumen (MB) layer having an outer surface and an inner surface .

[0186] In another embodiment, the inner surface of the first MB layer is contactably attached to the outer surface of the first insulation layer without any fastening mechanism, through a plurality of fasteners, through an adhesive layer, through a thermal application, or a combination of techniques thereof. In yet another embodiment, at least one of the fasteners from the plurality of fasteners penetrates the first MB layer, the first insulation layer, as well as the roof deck. In another embodiment, the first insulation layer optionally exceeds the dimensions of the first MB layer from at least one of its edges to be a portion of an extension flap;

[0187] wherein said two IRS panels are contactably juxtaposed to or contactably attached to each other, wherein a seam layer is contactably attached in between the modified bitumen layers of the two panels placed side-by-side, wherein the width of the seam layer ranges from 0% to 25% of the width of the MB layer, wherein the 0% corresponds to the embodiment wherein the first MB layer and the corresponding first insulation layer of the first IRS panel are flush with each other, and wherein the first MB layer and the corresponding first insulation layer of the second IRS panel are flush with each other, and wherein the two panels are contactably attached or juxtaposed to each other. In yet another embodiment, at least one fastener of the plurality of fasteners is a metal fastener.

[0188] Embodiment 7

[0189] As shown in Fig. 7, in one embodiment, this invention relates to a panel assembly comprising at least two panels, a first IRS panel and a second IRS panel for construction purposes, each panel comprising the following layers:

[0190] (i) a first insulation layer having an outer surface and an inner surface;

[0191] (ii) a first modified bitumen (MB) layer (or the base layer) having an outer surface and an inner surface, and

[0192] (iii)a second modified bitumen layer (MB2) layer, contactably attached to the MB layers, with or without the seam layer.

[0193] In another embodiment, the inner surface of the first MB layer can contactably attached to the outer surface of the first insulation layer without any fastening mechanism, through a plurality of fasteners, through an adhesive layer, through a thermal application, or a combination thereof. I another embodiment, at least one of the fasteners from the plurality of fasteners penetrates the first MB layer, the first insulation layer, and the roof deck. In yet another embodiment, the first insulation layer optionally exceeds the dimensions of the first MB layer from at least one of its edges to be a portion of an extension flap. In yet another embodiment, the first and second IRS panels are contactably juxtaposed to or contactably attached to each other on their sides. In a further embodiment, a seamPCT Application BH Ref.: 092457.000613

[0194] layer is contactably attached in between the modified bitumen layers of the two panels placed side-by-side. In yet another embodiment, the width of the seam layer ranges from 0% to 25% of the width of the MB layer, wherein the 0% corresponds to the embodiment wherein the first MB layer and the corresponding first insulation layer of the first IRS panel are flush with each other, and wherein the first MB layer and the corresponding first insulation layer of the second IRS panel are flush with each other, and wherein the two panels are contactably attached or juxtaposed to each other. In another embodiment, the MB2 layer (or the cap layer) is placed contactably positioned or attached on top of the MB layer, that is, the base, and on the side of the MB layer that is opposite to the side where the first insulation layer is located, and wherein the MB2 layer is amenable to adhesion and softening thru a thermal treatment. In yet another embodiment, at least one fastener of the plurality of fasteners is a metal fastener.

[0195] Embodiment 8

[0196] As shown in Fig. 8, this invention pertains to a first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:

[0197] (i) a first insulation layer having an outer surface and an inner surface;

[0198] and

[0199] (ii) a first modified bitumen (MB) layer having an outer surface and an inner surface .

[0200] In another embodiment, the inner surface of the first MB layer can be contactably attached to the outer surface of the first insulation layer, optionally through an adhesive layer. In yet another embodiment, the first MB layer optionally exceeds the dimensions of the first insulation layer from at least one of its edges to be a portion of the extension flap, and wherein the first insulation layer optionally exceeds the dimensions of the first MB layer from at least one of its edges to be a portion of a second extension flap. In yet another embodiment, the MB layer is contactably attached to the first insulation layer without any fastening mechanism, through an adhesive, through a plurality of fasteners, thermally, or a combination of techniques thereof. In yet another embodiment, at least one fastener from the plurality of fasteners is a metal fastener.

[0201] Embodiment 9

[0202] As shown in Fig. 9, this invention relates to a first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:

[0203] (i) a first insulation layer having an outer surface and an inner surface;

[0204] and

[0205] (ii) a first modified bitumen (MB) layer having an outer surface and an inner surface .PCT Application BH Ref.: 092457.000613

[0206] In another embodiment, the inner surface of the first MB layer is contactably attached to the outer surface of the first insulation layer, optionally through an adhesive layer, a plurality of fasteners, thermally, or a combination thereof. In yet another embodiment, the MB layer is contactably attached to the first insulation layer without any fastening mechanism, through an adhesive, through a plurality of fasteners, through thermal application such as a blow torch, or a combination thereof. In yet another embodiment, at least one fastener from the plurality of fasteners is a metal fastener.

[0207] Embodiment 10

[0208] As shown in Fig. 10, this invention relates to a first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:

[0209] (i) a first insulation layer having an outer surface and an inner surface;

[0210] and

[0211] (ii) a first structurally stable (SS) panel having an outer surface and an inner surface, wherein the inner surface of the first MB layer is contactably attached to the outer surface of the first insulation layer, without any fastening mechanism, optionally through an adhesive layer, a plurality of fasteners, or a combination thereof.

[0212] In another embodiment, the SS panel comprises gypsum. In yet another embodiment, at least one fastener from the plurality of fasteners is a metal fastener.

[0213] Embodiment 11

[0214] As shown in Fig. 11, this invention pertains to a first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:

[0215] (i) a first insulation layer having an outer surface and an inner surface;

[0216] (ii) a first structurally stable (SS) panel having an outer surface and an inner surface,

[0217] wherein the inner surface of the first SS layer is contactably attached to the outer surface of the first insulation layer, without any fastening mechanism, optionally through an adhesive layer, a plurality of fasteners, or a combination thereof; and

[0218] (iii) a first modified bitumen (MB) layer having an outer surface and an inner surface,

[0219] wherein the inner surface of the first MB layer (base sheet) is contactably attached to the outer surface of the first SS layer, optionally through an adhesive layer, a plurality of fasteners, thermally, or a combination thereof.

[0220] In another embodiment, the SS panel comprises gypsum. In yet another embodiment, at least one fastener from the plurality of fasteners is a metal fastener.PCT Application BH Ref.: 092457.000613

[0221] Embodiment 12

[0222] As shown in Fig. 12, in this embodiment, the invention relates to a first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:

[0223] (i) a first insulation layer having an outer surface and an inner surface;

[0224] (ii) a first structurally stable (SS) panel having an outer surface and an inner surface,

[0225] wherein the inner surface of the first SS layer is contactably attached to the outer surface of the first insulation layer, without any fastening mechanism, optionally through an adhesive layer, a plurality of fasteners, or a combination thereof;

[0226] (iii) a first modified bitumen (MB) layer having an outer surface and an inner surface,

[0227] wherein the inner surface of the first MB layer (base sheet) is contactably attached to the outer surface of the first SS layer, optionally through an adhesive layer, a plurality of fasteners, thermally, or a combination thereof; and

[0228] (iv) a second modified bitumen (MB2) layer (cap sheet) having an outer surface and an inner surface, wherein the inner surface of the second MB layer is contactably attached to the inner surface of the first MB layer, without any fastening mechanism, optionally through an adhesive layer, a plurality of fasteners, or a combination thereof.

[0229] In another embodiment, the SS panel comprises gypsum. In yet another embodiment, at least one fastener from the plurality of fasteners is a metal fastener.

[0230] Embodiment 13

[0231] As shown in Fig. 13, in this embodiment, the present invention relates to a first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:

[0232] (i) a first insulation layer having an outer surface and an inner surface;

[0233] (ii) a first structurally stable (SS) panel having an outer surface and an inner surface,

[0234] wherein the inner surface of the first SS layer is contactably attached to the outer surface of the first insulation layer, without any fastening mechanism, optionally through an adhesive layer, a plurality of fasteners, or a combination thereof;

[0235] (iii) a first modified bitumen (MB) layer having an outer surface and an inner surface,

[0236] wherein the inner surface of the first MB layer (base sheet) is contactably attached to the outer surface of the first SS layer, optionally through an adhesive layer, a plurality of fasteners, thermally, or a combination thereof; and

[0237] (iv) a second modified bitumen (MB2) layer (cap sheet) having an outer surface and an inner surface,PCT Application BH Ref.: 092457.000613

[0238] wherein the inner surface of the second MB layer is contactably attached to the inner surface of the first MB layer, without any fastening mechanism, optionally through an adhesive layer, a plurality of fasteners, or a combination thereof; and

[0239] wherein the first MB layer extends at least on one of its edges beyond the first SS layer to create a first extension flap, wherein the extension flap is from about 0% to about 20% of the width of the first SS layer, and / or

[0240] wherein the second MBs layer extends at least on one of its edge beyond the first SS layer to create a second extension flap, wherein the second extension flap is from about 0% to about 20% of the width of the first SS layer,

[0241] wherein the width of the first extension flap is the same or different from the width of the second extension flap.

[0242] In another embodiment, the SS panel comprises gypsum. In yet another embodiment, at least one fastener from the plurality of fasteners is a metal fastener.

[0243] The layers used in constructing the IRS panels described in the embodiments above are described in detail below.

[0244] II. Insulation Laver

[0245] Insulation Foam

[0246] Thermal insulation sheathing offers thermal barrier properties desirable for enclosures that have regulated temperatures, including houses, offices, refrigerated containers, and the like. Extruded polymer foam articles such as polystyrene foam boards are thermal insulation materials for use in such enclosures including building and construction applications as well as thermal insulation containers. See for example, W02018098570A1.

[0247] The thermal insulation sheathing that can be cut up into boards are commonly used to enhance insulation of building structures. Relatively thin (about ! inch to about 3.0 inches), rectangular panels of foam board are commonly placed between the dry wall and building exteriors such as stone, brick, wood, stucco, and the like. Insulation boards employed in such applications may include, but are not limited to, those utilizing polyisocyanurate foam and extruded polystyrene, polyolefin, and polyurethane foams and beads.

[0248] It would be advantageous if such insulation sheathing also provided a weather-resistive barrier that aids in removal of moisture and waterproofing.PCT Application BH Ref.: 092457.000613

[0249] The thermal insulation sheathing comprises foams of thermoplastic resins such as, for example, polystyrene and polyethylene, and polyurethane. Foams can be open-celled, close-celled and / or a mixed-cell structure.

[0250] In one embodiment, the insulation foams are made of extruded polystyrene, expanded polystyrene, polyethylene, polypropylene, or polyurethane.

[0251] They are useful industrial products because of their excellent heat -insulating, cushioning and other properties. These foams have found acceptance over the years in such applications as thermal insulation and cushioning as well as raw material for the fabrication of various shaped articles. The preparation of thermoplastic foams by extruding a heat-plastified mixture of a thermoplastic resin and a blowing agent is well known in the art and is described in U.S. Pat. Nos. 2,740,157; 3,067,147; 3,413,387; 3,413,388; 3,431,163; 3,431,164; 3,954,929 and 3,966,381 and Canadian Pat. No. 451,864. Similarly, various methods of preparing open or close-celled expanded polystyrene and other thermoplastic resins are described in art such as U.S. Pat. Nos. 3,243,485; 3,922,328; 4,399,086; 5049328; 5,271,886; and 7,358,280; U. S. Pat. App. Pub. Nos. US20020117769, US20130266766; and EPO patents EP0242191A2 and EP1995273A2. All art cited in this document is incorporated by reference as if fully set forth herein.

[0252] Current weather-resistive barriers that claim drainage capability are sheet fdms that have an external application of adhesive or coating that provides an offset for potential drainage.

[0253] In U.S. Pat. No. 6,355,333, granted to Waggoner et al., a Construction Membrane is taught. The membrane is described as resisting liquid and air penetration, being moisture vapor permeable, and being provided with integral drainage channels. The disclosed exterior wall construction which incorporates this membrane may be faced with stucco, siding, brick, or stone.

[0254] An Exterior Building Cladding Having Rigid Foam Layer With Drain Channels is shown in U.S. Pat. No. 6,886,301, granted to Schilger. Both the inside and the outside faces of the rigid foam insulation layer are provided with vertical channels 21 to remove moisture by way of thin channels 22. Exterior water penetration drains to the bottom of channels 22, and exits the wall construction by means of a drain wick 28 and flashing 25.

[0255] In Published Patent Application No. US 2011 / 0296781, owned by McCary, an Insulating Finishable Panel is illustrated. This construction employs a rigid-faced foam cored panel, which, in one embodiment includes foam air spacers adhered to the panel's radiant reflective surface. In another arrangement, attached foam air spacers create an air space between the insulation and the radiant reflective surface.

[0256] In Published Patent Application No. US 2008 / 0034690, to Gartz et al., an Underlayment With Improved Drainage is disclosed. The underlayment may include a plurality of vertical channels, and funnels atPCT Application BH Ref.: 092457.000613

[0257] respective top and bottom edges. The funnels are provided to compensate for misalignment of vertically stacked underlayment panels.

[0258] Notwithstanding coats of paint and moisture sealant applied to the exterior layer of a stucco wall, moisture still manages to penetrate the stucco over time, and collect on layers of material within the wall. Known prior art construction methods provide moisture barriers and attempt to allow the drainage of accumulated moisture. However, these methods have proven inadequate, and stucco walls continue to fail from moisture intrusion and accumulation, allowing mold to form and causing wood to rot. The exterior stucco wall construction disclosed herein, provides improved drainage of the moisture which has penetrated the wall and collects therein on materials and structures. Improved longevity and integrity of the stucco wall system is thereby provided.

[0259] The insulation layer can comprise any suitable insulation material conventionally known to one of ordinary skill in the art. For example, the insulation layer can comprise a foam polymer insulation, including for example and without limitation, polyisocyanurate foam, polystyrene foam, polyurethane foam, or any combination thereof. In further exemplary aspects, the foam insulation layer comprises polyisocyanurate foam. In still further aspects, the foam insulation layer can comprise a blend or combination of a polyisocyanurate and polyurethane foam.

[0260] The foam insulation layer can comprise extruded foam, expanded foam, or a combination thereof. As one of ordinary skill in the art will appreciate, extruded foams can be prepared by melting a suitable polymer material, incorporating a blowing agent to yield a foamed gel, and extruding the foamed gel through a die to form the desired foam layer. Expanded foams can be prepared by subsequent expansion of beads containing a blowing agent, wherein the expanded beads are molded at the time of expansion to form the desired foam layer.

[0261] The foam insulation can have any desired density. For example, the foam insulation can have a density of at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or even at least about 20 pounds per cubic feet (pcf) according to ASTM D1622. In further aspects, the foam insulation can have a density in the range of about 1 pcf to about 20 pcf. In still further aspects, the foam insulation density can be any desired value within any range derived from any of the above exemplified values, including, for example, a density in the range from about 2 to about 5 pcf, or from about 1 to about 10 pcf.

[0262] The foam insulation can be either closed cell or open cell. Open cell foam is more likely to let water vapor condense inside the cells, thereby reducing the insulation value. Thus, in further exemplary aspect, the foam insulation is closed cell. In a further aspect, the foam insulation is greater than about 50, 60, 70, 80, or even greater than about 90% closed-cell according to ASTM D2856.

[0263] Since water can negatively impact thermal performance, the foam insulation preferably exhibits limited or substantially no water absorption. For example, the foam insulation exhibits a water absorption ofPCT Application BH Ref.: 092457.000613

[0264] less than about 10, 9, 8, 7, 6, 5, 4, 3, 2, or even less than about 1% according to ASTM C209. In a further aspect, the foam insulation exhibits a water absorption of less than about 10, 9, 8, 7, 6, 5, 4, 3, 2, or even less than about 1% according to ASTM C2842. In a still further aspect, the foam insulation can exhibit a water absorption in the range of about 10 to about 0%. In a yet further aspect, the water absorption can be any desired value within any range derived from any of the above exemplified values, including, for example, a water absorption in the range from about 0 to about 5%, or from about 1 to about 3.5%.

[0265] Moreover, the foam insulation layer can have any desired water vapor permeance (or transmission) value. For example, the water vapor permeance can be about 20, 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, or even about 0 perms according to ASTM E96. In a further aspect, the water vapor permeance can be in the range of about 0 to about 20 perms. In a still further aspect, the water vapor permeance can be any desired value within any range derived from any of the above exemplified values, including, for example, a water vapor permeance in the range from about 0 to about 2 perms, or from about 1 to about 5 perms.

[0266] The insulation layer can have any desired thickness (t). This thickness (t) can be customized to fit any particular application and desired thermal resistance. For example, and without limitation, the thickness of the foam insulation layer can be in the range of from about 0.25 in. (! ") to about 3 in. (3"). In further aspects, the thickness can be from about 0.5 in. to about 1 in. Depending on the intended application, the panel can have any desired thermal resistance value (R-value). For example, the panel can have an R-value of at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25 according to ASTM C1289-02. In a further aspect, the R-value can be in the range of about 1 to about 25. In still further aspects, the R-value can be any desired value within any range derived from any of the above exemplified values, including, for example, R-value in the range from about 1 to about 10, or from about 3 to about 7.

[0267] In various aspects, the insulation layer can optionally comprise a membrane layer. The insulation membrane layer can comprise radiant barrier material, such as metal foil, for example, aluminum foil, polymeric film or fabric, paper, or cellulosic material, reinforcing scrim, such as fiberglass scrim, or a combination thereof. In some aspects, the membrane layer comprises a single or multi-layered material which can be a laminate in which a backing material is laminated to a foam insulation layer. In other aspects, one or more optional additives can also be incorporated into or otherwise applied to the foam insulation layer. Exemplary and non-limiting additives can include flame retardants, colorants, ultraviolet absorbers, textured coatings, and the like as well as any combinations thereof.

[0268] The insulation layer can be secured to the inward facing surface of the panel, for example, by any conventionally used adhesive material known in the art to be compatible for use with foam insulation. For example, according to non-limiting aspects of the invention, the adhesive can be selected from aPCT Application BH Ref.: 092457.000613

[0269] phenol-formaldehyde resin, hot-melt adhesive, polyvinyl acetate (PVA) resin, or any combination thereof. In still a further aspect, the adhesive can be isocyanate-based.

[0270] The insulated panels disclosed herein can exhibit improved physical strength and durability over traditional sheathing panels or foam panels. Thus, in one aspect, the inventive insulated panels can exhibit enhanced structural strength and dimensional stability when compared to a conventional or reference sheathing panel in the absence of the insulation layer when exposed to substantially the same environmental and / or physical forces under substantially similar conditions. To that end, the foam insulation layer can have a dimensional stability of about less than 5, 4, 3, 2, or even less than about 1% according to ASTM D2126. In a further aspect, the dimensional stability is preferably about less than 2%. The foam insulation layer can also have any desired compressive strength. For example, the foam insulation layer can have a desired compressive strength of at least about 1, 5, 10, 15, 20, 25, 30, 35, 40 pounds per square inch (psi) according to ASTM DI 621. In a further aspect, the compressive strength can be in the range of about 1 to about 40 psi. In a still further aspect, the compressive strength can be any desired value within any range derived from any of the above exemplified values, including, for example, a compressive strength in the range from about 15 to about 30 psi, or from about 20 to about 25 psi. Likewise, the foam insulation layer can have any desired tensile strength. For example, the foam insulation layer can have a tensile strength of greater than about 300, 400, 500, 600, 700, 800, 900, 1000, 1500, 2000 pounds per cubic foot (pcf) according to ASTM DI 623. In a further aspect, the tensile strength can be in the range of about 300 to about 2000 pcf. In a still further aspect, the tensile strength can be any desired value within any range derived from any of the above exemplified values, including, for example, a tensile strength in the range from about 500 to about 1000 pcf, or from about 600 to about 800 pcf.

[0271] In further aspects, the structural properties of the disclosed insulated panels make the insulated panels suitable for use in numerous structural applications, while still providing improved thermal performance. For example, in one aspect, the inventive insulated panels can be used as braced wall panels, when used in accordance with 2006 IBC Section 2308.3 and 2006 IRC Section R602.10.1. In another aspect, the inventive insulated panels are considered equivalent to Construction Method 3 described in Section 2308.9.3 of the 2006 IBC and Section R602.10.3 of the 2006 IRC. In another aspects, the inventive insulated panels are suitable for use an alternative to wood structural panels in the construction of wood shear walls, when installed in accordance with 2006 IBC Section 2305.3. It should be noted that all references cited above, and otherwise, in this specification are incorporated in this specification as if they were fully set forth herein.

[0272] In one embodiment, the foam insulation is expanded Polystyrene (EPS), Extruded Polystyrene (XPS), Graphite Polystyrene (GPS), or polyisocyanurate foam insulation.PCT Application BH Ref.: 092457.000613

[0273] Expanded Polystyrene Insulation, more commonly referred to as EPS, is a closed cell insulation made commonly with of 98% trapped air and only 2% plastic. In one embodiment, this invention relates to a flat board, a contoured shape, or a combination of flat and contoured shaped EPS.

[0274] Extruded Polystyrene, referred to as XPS, is a closed cell insulation product commonly used in remodeling and new construction applications. In one embodiment, this invention relates to a flat board, a contoured shape, or a combination of flat and contoured shaped XPS.

[0275] Graphite polystyrene insulation, or GPS, is made from Neopor beads, patented and manufactured by BASF. Neopor gives GPS insulation a dark gray appearance and higher r-value than traditional EPS insulation products. In one embodiment, this invention relates to a flat board, a contoured shape, or a combination of flat and contoured shaped GPS.

[0276] Polyisocyanurate foam boards may include closed-cell polyisocyanurate (polyiso) foam insulation. This is described, for example, in U.S. Patent No. 10829939B2, which is incorporated by reference herein. In one embodiment, this invention relates to a system of panels described herein, wherein at least one panel comprises EPS, or at least one panel comprises XPS, or at least one panel comprises GPS, or at least one panel comprises polyisocyanurate foam, or at least a combination of two out of the four panels, three of the four panels, or all four panels. In another embodiment, the panels may be organized adjacent each other or separate from each other.

[0277] In one embodiment, this invention relates to an insulation sheathing system that comprises two insulation sheathing panels: a first insulation sheathing panel and a second insulation sheathing panel. The two panels are juxtaposed side by side in one plane. Each insulation sheathing panel comprises the insulation foam layer and the fire-proofing layer as described previously.

[0278] In one embodiment, this invention relates to an insulation sheathing system that comprises two insulation sheathing panels: a first insulation sheathing panel and a second insulation sheathing panel. The two panels are juxtaposed side by side in one plane. Each insulation sheathing panel comprises the insulation foam layer and the fire-proofing as described previously.

[0279] In one embodiment, the panel has more than 2 sides. Stated differently, the present invention envisions a panel comprising, the following sides: 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20. In one embodiment of the invention, the panel has a curved shape, for example, it is circular, or oblong shaped or a semi-circle shaped. In one embodiment of the invention, the panel has at least one side that is not linear but has a curved shape.

[0280] In one embodiment, the multiple-sided panel has all sides that are equal or at least two sides that are equal or no sides that are equal in length.PCT Application BH Ref.: 092457.000613

[0281] This invention envisions an insulation sheathing panel system comprising at least two panels wherein a first panel is irregular shaped, but the adjacent juxtaposing second panel neatly fits with the irregular shape of the first panel.

[0282] In one embodiment, the insulation panel system comprises more than one square or a rectangular panel, wherein each side of the panel has a tongue or groove configuration.

[0283] In one embodiment, the insulation sheathing includes extruded polystyrene, polyisocyanurate, polyolefin, and polyurethane foams and beads.

[0284] III. Structurally Stable Panel

[0285] The structurally stable panels are an integral part of the IWS panel and is generally contactably and planarly adjacent the insulation layer. They can be made of wood, lignocellulosics, OSB, compalite, MgO, MgSO4, gypsum, or a combination of one or more such elements.

[0286] A preferred SS panel comprises gypsum. By “gypsum panel” is meant that an SS panel comprises more than 25% by weight of gypsum.

[0287] The wood-composite panel comprising plant-based materials. As used herein, “wood” is intended to mean a cellular structure, having cell walls composed of cellulose and hemicellulose fibers bonded together by lignin polymer. “Wafer board” is intended to mean panels manufactured from reconstituted wood wafers bonded with resins under heat and pressure.

[0288] As used herein, “wood composite” or “wood composite material” it is meant a composite material that comprises wood and one or more other additives, such as adhesives or waxes. Non-limiting examples of wood composite materials include oriented strand board (“OSB”), waferboard, particleboard, chipboard, medium-density fiberboard, plywood, and boards that are a composite of strands and ply veneers. As used herein, “flakes” and “strands” are considered equivalent to one another and are used interchangeably. A non-exclusive description of wood composite materials may be found in the Supplement Volume to the Kirk-Othmer Encyclopedia of Chemical Technology, pp. 765-810, 6thedition.

[0289] As used herein, “structural panel” is intended to mean a panel product, commonly composed of wood which, in its commodity end use, is essentially dependent upon certain mechanical and / or physical properties for successful end use performance such as plywood. A non-exclusive description may be found in the PS-2-92 Voluntary Product Standard.

[0290] The panel can comprise oriented strand board, plywood, particleboard, chipboard, medium -density fiberboard, or waferboard.PCT Application BH Ref.: 092457.000613

[0291] The structurally stable panel can also comprise at least one plant-based material, said other plant-based material are described as below:

[0292] grass, including perennial grass, switchgrass such as Panicum virgatum L, Miscanthus, Sorghum, sugarcane, millets, Napier grass, giant reed, and other forage and turf grasses, subalpine grasses, native grass, sedge, rush include Agrostis exarata (Spike Bentgrass), Ammophila arenaria (European sand dune or beach grass), Ammophila breviligulata (American beach grass), Ammophila champlainensis Seymour, Ammophila maritima, Beckmannia zyzigachne (American Sloughgrass), Bromus carinatus (California Brome), Bromus vulgaris (Columbia Brome), Carex densa (Dense-Headed Sedge), Carex feta (Green-Sheathed Sedge), Carex leporina (Harefoot Sedge), Carex lenticularis (=C. kelloggii) (Shore Sedge), Carex lyngbyel (Lyngby Sedge), Carex macrocephala (Big Headed Sedge), Carex obnupta (Slough Sedge), Carex pansa (Foredune Sedge), Carex unilateralis (One-Sided Sedge), Deschampsia caespitosa (Tufted Hair Grass), Eleocharis palustis (Creeping Spike rush), Elymus glaucus (Blue Wild Rye), Festuca idahoensis var. roemeri (Roemer's Fescue), Festuca rubra var. littoralis (Shore Fescue), Festuca subulata (Bearded Fescue), Glyceria elata (Tall Mannagrass), Glyceriaoccidentalis (Western Mannagrass), Hordeum brachyantherum (Meadow Barley), Juncus efftisus (Soft Rush), Juncus patens (Spreading Rush), Juncus tenuis (Slender Rush), Lozula campestris (Woodrush), Phalaris arundinacea (Reed Canary Grass), Phalaris aquatica, Phalaris tuberosa (Staggers Grass), Phalaris canariensis, Poa Macrantha (Dune Bluegrass), ReGreen (Sterile Hybrid Wheat), Scirpus acutus (Hardstem Bullrush), Scirpus americanus, Scirpus cyperinus, Scirpus maritimus (Seacoast Bullrush), Scirpus microcarpus, Scirpus validus, Sparaganuim eurycarpum (Giant Burreed), Triglochin maritinum (Seaside Arrowgrass), Typha latifolia (Cattail), Alopecuris geniculatus, Carex pachystachya, Carex stipata (grass like), Danthonia califomica, Eleocharis ovata (grass like), Glycaria grandis, Juncus acuminatus, Juncus bolanderi and Juncus ensifolius (Daggar leaf rush). By way of example, other grasses include the Lily of the Nile (Agapanthus africanus), white fountain grass (Pennisetum ruppellii), muhly grass (Muhlenbergia capillaris), African iris (Dietes vegeta), podocarpus (Podocarpus macrophyllus), wax myrtle (Myrica cerifera), Aztec grass (Ophiopogon intermedins argenteomarginatus), mondo grass (Ophiopogon japonicus), evergreen giant (Liriope muscan), evergreen Paspalum (Paspalum quadrifarium) and sand cord grass (Spartina bakerii).

[0293] Further the structurally stable panel comprises other plant-based materials, said other plant-based materials comprise flax straw, which is flax fibers and flax shives produced from processing waste flax straw. Waste flax straw is made during the harvesting of flaxseeds from flax plants. The flax straw includes a mixture of flax fibers and flax shives. In another embodiment, the lignocellulosic component includes bio-waste cotton (Gossypium hirsutum L.) stalks and underutilized paulownia (paulowniaPCT Application BH Ref.: 092457.000613

[0294] fortunie). In yet another embodiment, the wood composite includes waste stone pine (Pinus pinea L.) cones, needle litter of Scotch pine (Pinus sylvestris L.), com stalks, vine pruning stalks, sycamore leaves, reed stem, or hevea brasiliensis clones. In yet another embodiment, the lignocellulosic component comprises com stover, rice straw, wheat straw, barley straw, oat straw, rape seed straw, siteria grass, yukka fibre, lemongrass, jute, sisal, bamboo, pine needles, lupins, kenaf, coir fiber, coconut husks, cotton stalks, coffee husks, ground nut husks, areca nut husks, casaurina leaves, banana leaves and banana stem.

[0295] In one embodiment, the structurally stable panel is a composite board such as the EcoStorm® coverboard obtained from Carlisle Corporation of Mechanicsburg, Pennsylvania. The EcoStorm® coverboard is an engineered composite building material made from a blend of plastic and cellulose fiber. In one embodiment of the invention, the composite board is sourced from post -industrial and post-consumer waste streams. In another embodiment, such composite board is a durable, moisture and mold resistant building material.

[0296] IV. Modified Bitumen Layer

[0297] Modified Bitumen is asphalt with rubber or plastic polymers added. These polymers provide extra strength, flexibility, and durability. During manufacture, plastics or rubbers are added to the bitumen while heating, modifying its properties to give it a higher softening point and greater elasticity. Copolymers commonly used to modify asphalt include atactic polypropylene (APP), styrene -butadiene-styrene (SBS), styrene-butadiene rubber (SBR), and styrene-ethylene-butylene-styrene (SEBS).

[0298] The two main types of modified bitumen sheets are as follows:

[0299] APP Membranes

[0300] Often referred to as “plastic asphalt,” atactic polypropylene (APP) membranes are composed of asphalt mixed with plasticized polymers that exhibit elasticity under elevated temperatures. APP offers resistance to UV rays. APP is another rubber polymer used to give a base sheet extra durability and flexibility. It is also flexible at lower temperatures, enlarging the installation window for roofing contractors. If applied with heat, APP base sheets will need slightly higher temperatures than SBS base sheets.

[0301] SBS Membranes

[0302] SBS, or styrene-butadiene-styrene, is akin to “elastic” or “rubberized” asphalt in the context of roofing. This membrane blends asphalt with polymerized rubber, providing natural flexibility, elasticity, and durability. SBS allows this fiberglass base sheet to remain flexible in colder weather, for ease ofPCT Application BH Ref.: 092457.000613

[0303] installation. It also improves moisture resistance and durability. SBS is an excellent choice for buildings with roofs that undergo significant expansion and contraction due to extreme temperature variations or those exposed to high winds.

[0304] In one embodiment, modified bitumen are long rolls of asphalt-based materials, that can be heat-welded, self-adhering, asphalt-adhered, or installed with adhesive for application as membrane roofs. Asphalt is mixed, saturated, or coated with polymers such as APP or SBS, then applied to fiberglass, felt, reinforced polyester mat, composite reinforcement, or with the seams sealed by locally melting the asphalt with heat, hot mopping of asphalt, or adhesive. This is asphalt enhanced with plastic or rubber polymer.

[0305] Modified bitumen can be used as a base sheet or a cap sheet. Generally, a roofing base sheet is the bottom waterproofing layer on a multilayer roofing membrane system and the capsheet is the top. In one embodiment, the base sheets can be impregnated with unmodified asphalt, or they may be impregnated with modified bitumen, a high-performance asphalt. The sheets are surfaced with heat-weldable film, sand or a release film depending on the application requirements.

[0306] A low-slope roof is generally covered with a minimum of two sheets: a base sheet and a cap sheet. The base sheet provides waterproofing and a top surface that can bond with the cap sheet. The cap sheet provides color, protection from fire, ultraviolet (UV) radiation protection and resistance to mechanical abuse. The base sheet and cap sheet must be designed to work together.

[0307] In one embodiment, the modified bitumen is supplied in membrane rolls, and is applied directly to the substrate using an adhesive. Modified bitumen is commonly applied through heat welding (torch), mopping in hot asphalt, cold-process adhesive, or self-adhering membranes. There are several ways of connecting pieces of this material. The most common method for bonding seams is by torch -application, however the options of hot-mopping, using cold adhesive, and self-adhering materials are still sometimes used.

[0308] In one embodiment, to prepare a base sheet, a tough fiberglass nonwoven mat is used. The asphaltic compounds are modified with either SBS or APP copolymers. After proper mixing, the bitumens are applied to the mat. The mat is saturated or coated with the specific bitumen needed for the end product.

[0309] V. Weather-Resistive Barrier Laver

[0310] By “weather-resistive barrier layer” (“WRB layer”) is meant the external house-wrap layer that provides barrier properties but may have water vapor permeability. House wraps are described for example in U.S. Patent Nos. 6,901,712.PCT Application BH Ref.: 092457.000613

[0311] In one embodiment, the WRB layer is a perforated aluminum layer with a bituminous backing also known as the perforated waterproofing membrane (PWPM) Layer. The PWPM layer in one embodiment is a self-adhesive bituminous waterproofing membrane that possesses most effective ventilating characteristics. It is produced from SBS modified bitumen which exhibits impressive elasticity and enhanced viscoelastic properties even at very low temperatures (-15°C), and special additives that give the membrane self-adhesive properties, hence the ability to stick very easily to a suitably prepared substrate without the need of a torch.

[0312] In one embodiment, the PWPM layer weights from 0.5 to 4 kg / m2, is reinforced with glass-fleece, with its top cover being quartz sand and its undercover a fully-adhered perforated aluminum foil or a perforated glass-fleece. The undercover is protected by a siliconized removable PE paper. In one embodiment, the PWPM layer is used. In that embodiment, the WRB layer described herein can also be used.

[0313] The perforated aluminum foil is an excellent under layer to accommodate the thermal expansions of the substrate and create vapor pressure relief areas. The perforations in the aluminum foil allow the special type of polymer modified bitumen to stick to the surface beneath. This way, the PWPM layer is applied by means of “regular spot-welding.” PWPM is categorized as a thermos-adhesive roofing membrane, meaning that the fastening of PWPM layer to the substrate base is fully completed when the top waterproofing layer is torched on.

[0314] In one embodiment, the WRB layer is a perforated sheet air barrier membrane, which is permeable to water vapor, and which can be adhered to a substrate, substantially over its entire area, by virtue of an adhesive deposited on one side of the sheet. In the present invention, the substrate is an insulation layer. In yet another embodiment, the WRB layer is a water vapor permeable, air barrier sheet membrane which can be installed with or without the use of mechanical fasteners, nails, screws, or tapes to provide an air barrier system with a continuous plane of air tightness.

[0315] In another embodiment, the WRB layer has an adhesive backed water vapor permeable sheet membrane that can perform as a barrier to the infiltration of liquid or bulk water as from wind -driven rain, when used in roof assemblies.

[0316] In another embodiment, the WRB layer is a self-adhering, water vapor permeable, air and moisture barrier sheet for structural surfaces of buildings, comprising (i) an air and moisture barrier membrane which is water vapor permeable, and (ii) has an adhesive applied to one side of the water vapor permeable membrane in a non-continuous film.

[0317] In accordance with a particular embodiment of the invention, there is provided a self-adhering sheet for structural surfaces, comprising, (a) an air and moisture barrier membrane having opposed first and second faces, said membrane being water vapor permeable, and (b) an adhesive applied to said secondPCT Application BH Ref.: 092457.000613

[0318] face in a non-continuous film to define a plurality of spaced-apart, non-adhesive-coated zones surrounded by an adhesive coated zone.

[0319] In yet another aspect of the invention, WRB layer is an article of manufacture comprising a self-adhering sheet of the invention having a strippable release sheet removably adhered to said second face with a non-continuous adhesive film.

[0320] WRB Laver— Vapor Permeable Membrane

[0321] The vapor permeable membrane of the invention is a flexible sheet or film, which is permeable to the passage of water in vapor form. The sheet or film may be microporous, microperforated or some other type of vapor permeable sheet or film.

[0322] A microporous sheet or film is a non-perforated continuous microfiber web with microscopic pores large enough for moisture vapor to pass through, but small enough to resist air and liquid water. Microperforated membranes depend on mechanical pin-perforations and / or film laminations to build in properties.

[0323] While both of the abovementioned types of sheet or film are permeable to water vapor, a sheet or film of the microporous type is preferred as this type is less permeable to the passage of water or moisture in liquid or bulk form.

[0324] Suitable microporous sheets or films are spunbonded or fibrous bonded polyolefin as described in U.S. Pat. Nos. 3,532,589 and 5,972,147, preferred polyolefins are polyethylene and polypropylene, one such microporous sheet is available commercially under the trade-mark Tyvek®; other suitable microporous sheets include oriented polymeric films as described in U.S. Pat. No. 5,317,035, and which comprise ethylene-propylene block copolymers; one such film is commercially available as Aptra®. The sheets or films may be reinforced with several types of scrim materials or may be laminated to other vapor permeable sheets or films, such as non-woven polypropylene or non-woven polyester for the purpose of improving strength and other physical properties.

[0325] In general, the membrane will typically have a thickness of 0.001 to 0.04, preferably 0.001 to 0.025 inches.

[0326] The WRB layer can extend at one or more edges of the panel as the extension flap, wherein the extension flap comprises a removably attached release liner on its back side.

[0327] In one embodiment, the extension flap of the WRB extends in length from about 0.2% of the minimum dimension of the panel to about 50% of the length of the maximum dimension of the panel. In one embodiment, the adhesive on the inner surface of the WRB that adheres to the wood layer is the same as the adhesive on the extension flap of the WRB having a removably attached release liner.PCT Application BH Ref.: 092457.000613

[0328] In one embodiment comprising the extension flaps or pre-applied tapes, the overhang is anywhere from 0.1 inches to 12 inches on any one or more edges of the panel. This is advantageous is minimizing or to eliminating the need for labor to tape the seams in the field.

[0329] VI. Optional Adhesive

[0330] The adhesive used herein can be a hot-melt adhesive, solvent based adhesive, water based adhesive or of other types such as UV cured polymer. The applied adhesive is preferably tacky, i.e., sticky and pressure sensitive. Suitable hot melt adhesives may contain such ingredients as polymers such as butyl rubber, styrene-butadiene-styrene (SBS), styrene-isoprene-styrene (SIS), styrene butadiene (SB), styrene-ethylene-butadiene-styrene (SEBS) and ethylene vinyl acetate (EVA); resins such as those of the hydrocarbon and rosin types, natural and petroleum waxes, oils, bitumen, and others. Solvent-based adhesives may contain ingredients such as those listed above, dissolved, or dispersed in a solvent vehicle. Water based adhesives would normally be based on emulsions of polymeric materials. Suitable polymeric materials would include vinyl acetate and acrylic polymers and copolymers such as vinyl acetate acrylic, ethylene vinyl acetate as well as styrene acrylic, vinyl chloride acrylic, vinyl versatate and others.

[0331] From a production standpoint, the preferred adhesives are of the hot melt type which are simply melted for application and need not emit solvent which is an environmental pollutant and may require re-condensation. Water based adhesives have the disadvantage that they generally require the additional use of drying ovens or heat lamps to evaporate the water.

[0332] The adhesive may suitably be applied at a thickness of 0.001 inches to 0.1 inch but is preferably applied at a thickness of 0.003 inches to 0.025 inches and most preferably at a thickness of 0.005 inches to 0.02 inches.

[0333] The WRB layer (for example, the PWPM layer) is adhered to an insulation layer or a panel, with an adhesive. The WRB layer extends beyond the panel dimensions in one or more directions away from the edges. For example, if the panel is rectangular, with the WRB layer attached to it. The WRB layer will extend at least 0.1 inch over the dimension of the rectangular panel on one or more sides. In these extension flaps of the WRB panel will be attached a release liner that is attached with an adhesive material, such that when more than one panel is abutted to each other, upon removal of the release liner the WRB layer adhered directly to the adjacent panel of the assembly and will seal the gaps between the two panels in the assembly.

[0334] Suitable release sheets are paper sheet, having a silicone release surface coating and some treated plastic films.PCT Application BH Ref.: 092457.000613 Adhesive described herein can be used to adhere various layers of the IRS membranes described herein.

Claims

1. PCT Application BH Ref.: 092457.000613CLAIMS1. A first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:(i) a first insulation layer having an outer surface and an inner surface;(ii) a first perforated waterproofing membrane (PWPM) layer having an outer surface and an inner surface, wherein the inner surface of the first PWPM layer or the side having the perforated aluminum sheet, is secured to the outer surface of the first insulation layer, optionally through an adhesive layer,wherein the first PWPM layer optionally exceeds the dimensions of the first insulation layer from at least one of its edges to form a portion of an optional extension flap, wherein the extension flap of the first PWPM layer further comprises a removably attached release -liner attached to the PWPM layer’s inner surface, and wherein the first PWPM layer comprises a modified bitumen layer and a perforated aluminum foil;and(iii) a first modified bitumen (MB) layer having an outer surface and an inner surface, wherein the inner surface of the first MB layer is secured to the outer surface of the first PWPM layer, optionally through an adhesive layer,wherein the first MB layer optionally exceeds the dimensions of the first insulation layer from at least one of its edges to be a portion of the optional extension flap.

2. A first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:(i) a first insulation layer having an outer surface and an inner surface;and(ii) a first modified bitumen (MB) layer having an outer surface and an inner surface, wherein the inner surface of the first MB layer is contactably attached to the outer surface of the first insulation layer, without any fastening mechanism, optionally through an adhesive layer, thermally, or a combination thereof,wherein the first MB layer optionally exceeds the dimensions of the first insulation layer from at least one of its edges to be a portion of the extension flap.PCT Application BH Ref.: 092457.0006133. A first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:(i) a first insulation layer having an outer surface and an inner surface;and(ii) a first modified bitumen (MB) layer having an outer surface and an inner surface, wherein the inner surface of the first MB layer is contactably attached to the outer surface of the first insulation layer without any fastening mechanism, through a plurality of fasteners, through an adhesive layer, thermally, or a combination thereof, and wherein the plurality of fasteners penetrates the first MB layer and the first insulation layer and into the roof deck;wherein the first insulation layer exceeds the dimensions of the first MB layer from at least one of its edges to be a portion of an extension flap.

4. The first IRS panel as recited above, wherein at least one fastener of the plurality of fasteners is a metal fastener.

5. A first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:(i) a first insulation layer having an outer surface and an inner surface;and(ii) a first modified bitumen (MB) layer having an outer surface and an inner surface, wherein the inner surface of the first MB layer is contactably attached to the outer surface of the first insulation layer without any fastening mechanism, through a plurality of fasteners, through an adhesive layer, or both, and wherein the plurality of fasteners penetrates the first insulation layer and not the first MB layer and into the roof deck;wherein the first insulation layer exceeds the dimensions of the first MB layer from at least one of its edges to be a portion of an extension flap.PCT Application BH Ref.: 092457.0006136. A first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:(i) a first insulation layer having an outer surface and an inner surface;and(ii) a first modified bitumen (MB) layer having an outer surface and an inner surface, wherein the inner surface of the first MB layer is contactably attached to the outer surface of the first insulation layer through a plurality of fasteners, through an adhesive layer, or both, and wherein at least one of the fasteners from the plurality of fasteners penetrates the first MB layer, the first insulation layer, and the roof deck; wherein the first insulation layer exceeds the dimensions of the first MB layer from at least one of its edges to be a portion of an extension flap.

7. The first IRS panel as recited above, wherein at least one fastener of the plurality of fasteners is a metal fastener.

8. A panel assembly comprising at least two panels, a first IRS panel and a second IRS panel for construction purposes, each panel comprising the following layers:(i) a first insulation layer having an outer surface and an inner surface;and(ii) a first modified bitumen (MB) layer having an outer surface and an inner surface, wherein the inner surface of the first MB layer is contactably attached to the outer surface of the first insulation layer without any fastening mechanism, through a plurality of fasteners, through an adhesive layer, thermally, or a combination thereof, and wherein at least one of the fasteners from the plurality of fasteners penetrates the first MB layer, the first insulation layer, and the roof deck;wherein the first insulation layer optionally exceeds the dimensions of the first MB layer from at least one of its edges to be a portion of an extension flap; wherein said two IRS panels are contactably juxtaposed to or contactably attached to each other, wherein a seam layer is contactably attached in between the modified bitumen layers of the two panels placed side-by-side, wherein the width of the seam layer ranges from 0% to 25% of the width of the MB layer, wherein the 0% corresponds to the embodiment wherein the first MBPCT Application BH Ref.: 092457.000613layer and the corresponding first insulation layer of the first IRS panel are flush with each other, and wherein the first MB layer and the corresponding first insulation layer of the second IRS panel are flush with each other, and wherein the two panels are contactably attached or juxtaposed to each other.

9. The panel assembly as recited above, wherein at least one fastener of the plurality of fasteners is a metal fastener.

10. A panel assembly comprising at least two panels, a first IRS panel and a second IRS panel for construction purposes, each panel comprising the following layers:(i) a first insulation layer having an outer surface and an inner surface;(ii) a first modified bitumen (MB) layer (or the base layer) having an outer surface and an inner surface,wherein the inner surface of the first MB layer is contactably attached to the outer surface of the first insulation layer without any fastening mechanism, through a plurality of fasteners, through an adhesive layer, thermally, or a combination thereof, and wherein at least one of the fasteners from the plurality of fasteners penetrates the first MB layer, the first insulation layer, and the roof deck;wherein the first insulation layer optionally exceeds the dimensions of the first MB layer from at least one of its edges to be a portion of an extension flap; wherein said first and second IRS panels are contactably juxtaposed to or contactably attached to each other,wherein a seam layer is contactably attached in between the modified bitumen layers of the two panels placed side-by-side, wherein the width of the seam layer ranges from 0% to 25% of the width of the MB layer, wherein the 0% corresponds to the embodiment wherein the first MB layer and the corresponding first insulation layer of the first IRS panel are flush with each other, and wherein the first MB layer and the corresponding first insulation layer of the second IRS panel are flush with each other, and wherein the two panels are contactably attached or juxtaposed to each other; and(iii) a second modified bitumen layer (MB2) layer, contactably attached to the MB layers, with or without the seam layer,PCT Application BH Ref.: 092457.000613wherein the MB2 layer (or the cap layer) is placed contactably positioned or attached on top of the MB layer and on the side of the MB layer that is opposite to the side where the first insulation layer is located, andwherein the MB2 layer is amenable to adhesion and softening thru a thermal treatment.

11. The panel assembly as recited above, wherein at least one fastener of the plurality of fasteners is a metal fastener.

12. A first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:(i) a first insulation layer having an outer surface and an inner surface;and(ii) a first modified bitumen (MB) layer having an outer surface and an inner surface, wherein the inner surface of the first MB layer is contactably attached to the outer surface of the first insulation layer, optionally through an adhesive layer, wherein the first MB layer optionally exceeds the dimensions of the first insulation layer from at least one of its edges to be a portion of the extension flap, and wherein the first insulation layer optionally exceeds the dimensions of the first MB layer from at least one of its edges to be a portion of a second extension flap.

13. The first IRS panel as recited above, wherein the MB layer is contactably attached to the first insulation layer without any fastening mechanism, through an adhesive, through a plurality of fasteners, thermally, or a combination thereof.

14. The first IRS panels as recited above, wherein at least one fastener of the plurality of fasteners is a metal fastener.

15. A first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:(i) a first insulation layer having an outer surface and an inner surface;PCT Application BH Ref.: 092457.000613and(ii) a first modified bitumen (MB) layer having an outer surface and an inner surface, wherein the inner surface of the first MB layer is contactably attached to the outer surface of the first insulation layer, optionally through an adhesive layer, a plurality of fasteners, thermally, or a combination thereof.

16. The first IRS panel as recited above, wherein the MB layer is contactably attached to the first insulation layer without any fastening mechanism, through an adhesive, through a plurality of fasteners, or a combination thereof.

17. The first IRS panels as recited above, wherein at least one fastener of the plurality of fasteners is a metal fastener.

18. A first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:(i) a first insulation layer having an outer surface and an inner surface;and(ii) a first structurally stable (SS) panel having an outer surface and an inner surface, wherein the inner surface of the first MB layer is contactably attached to the outer surface of the first insulation layer, without any fastening mechanism, optionally through an adhesive layer, a plurality of fasteners, or a combination thereof.

19. The first IRS panel as recited above, wherein the SS panel comprises gypsum.

20. The first IRS panels as recited above, wherein at least one fastener of the plurality of fasteners is a metal fastener.

21. A first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:(i) a first insulation layer having an outer surface and an inner surface;PCT Application BH Ref.: 092457.000613(ii) a first structurally stable (SS) panel having an outer surface and an inner surface, wherein the inner surface of the first SS layer is contactably attached to the outer surface of the first insulation layer, without any fastening mechanism, optionally through an adhesive layer, a plurality of fasteners, or a combination thereof; and (iii) a first modified bitumen (MB) layer having an outer surface and an inner surface, wherein the inner surface of the first MB layer (base sheet) is contactably attached to the outer surface of the first SS layer, optionally through an adhesive layer, a plurality of fasteners, thermally, or a combination thereof.

22. The first IRS panel as recited above, wherein the SS panel comprises gypsum.

23. The first IRS panels as recited above, wherein at least one fastener of the plurality of fasteners is a metal fastener.

24. A first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:(i) a first insulation layer having an outer surface and an inner surface;(ii) a first structurally stable (SS) panel having an outer surface and an inner surface, wherein the inner surface of the first SS layer is contactably attached to the outer surface of the first insulation layer, without any fastening mechanism, optionally through an adhesive layer, a plurality of fasteners, or a combination thereof;(iii) a first modified bitumen (MB) layer having an outer surface and an inner surface, wherein the inner surface of the first MB layer (base sheet) is contactably attached to the outer surface of the first SS layer, optionally through an adhesive layer, a plurality of fasteners, thermally, or a combination thereof; and(iv) a second modified bitumen (MB2) layer (cap sheet) having an outer surface and an inner surface,wherein the inner surface of the second MB layer is contactably attached to the inner surface of the first MB layer, without any fastening mechanism, optionally through an adhesive layer, a plurality of fasteners, or a combination thereof; andPCT Application BH Ref.: 092457.00061325. The first IRS panel as recited above, wherein the SS panel comprises gypsum.

26. The first IRS panels as recited above, wherein at least one fastener of the plurality of fasteners is a metal fastener.

27. A first integrated roofing system (IRS) panel for construction purposes, comprising the following layers:(i) a first insulation layer having an outer surface and an inner surface;(ii) a first structurally stable (SS) panel having an outer surface and an inner surface, wherein the inner surface of the first SS layer is contactably attached to the outer surface of the first insulation layer, without any fastening mechanism, optionally through an adhesive layer, a plurality of fasteners, or a combination thereof;(iii) a first modified bitumen (MB) layer having an outer surface and an inner surface, wherein the inner surface of the first MB layer (base sheet) is contactably attached to the outer surface of the first SS layer, optionally through an adhesive layer, a plurality of fasteners, thermally, or a combination thereof; and(iv) a second modified bitumen (MB2) layer (cap sheet) having an outer surface and an inner surface,wherein the inner surface of the second MB layer is contactably attached to the inner surface of the first MB layer, without any fastening mechanism, optionally through an adhesive layer, a plurality of fasteners, or a combination thereof; and wherein the first MB layer extends at least on one of its edges beyond the first SS layer to create a first extension flap, wherein the extension flap is from about 0% to about 20% of the width of the first SS layer, and / orwherein the second MBs layer extends at least on one of its edge beyond the first SS layer to create a second extension flap, wherein the second extension flap is from about 0% to about 20% of the width of the first SS layer,wherein the width of the first extension flap is the same or different from the width of the second extension flap.

28. The first IRS panel as recited above, wherein the SS panel comprises gypsum.PCT Application BH Ref.: 092457.00061329. The first IRS panels as recited above, wherein at least one fastener of the plurality of fasteners is a metal fastener.

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