Method for increasing wind uplift resistance of wood-framed roofs using closed-cell spray polyurethane foam

Abstract

The invention provides a method and structural member for securing a roof or an outer wall of a building against wind forces tending to lift the roof or outer wall off the building. A structural member has a panel, said panel comprising a plurality of spaced apart beam members, and a sheathing having an inner side and an outer side, the sheathing spanning a space between adjacent beam members and being attached to the beam members such that the inner side of the sheathing is in juxtaposition with the beam members. A layer of a rigid, closed cell foam comprising a polymer adhesive composition is on substantially the entirety of said beam members and substantially the entirety of the inner side of the sheathing such that the layer on the sheathing and the beam members is substantially continuous, and adheres the sheathing to the beam members.

1 . A method of securing a roof or an outer wall of a building against wind forces which comprises:
 a) providing a roof panel or outer wall panel, said roof panel or outer wall panel comprising a plurality of spaced apart beam members, and a sheathing having an inner side and an outer side, the sheathing spanning a space between adjacent beam members and being attached to the beam members such that the inner side of the sheathing is in juxtaposition with the beam members; and   b) spraying a layer of a foamable polymer adhesive composition onto at least a portion of side walls of said beam members and substantially the entirety of the inner side of the sheathing such that the layer on the sheathing and the beam members is substantially continuous;   c) allowing the foamable polymer adhesive composition to form a rigid, closed cell foam which adheres the sheathing to the beam members.   
   
   
       2 . The method of  claim 1  wherein the foamable polymer adhesive composition is a liquid. 
   
   
       3 . The method of  claim 1  wherein the beam members are attached to the sheathing by nails, screws, clips, or combinations thereof. 
   
   
       4 . The method of  claim 1  wherein the beam members comprise wood, wood composite, metal or combinations thereof. 
   
   
       5 . The method of  claim 1  wherein the sheathing comprises wood, oriented strand board, fibrous cement, fiberglass reinforced gypsum, expanded polystyrene, extruded polystyrene, polyisocyanurate, foam board or combinations thereof. 
   
   
       6 . The method of  claim 1  wherein the adhesive composition comprises a blowing agent comprising at least one of a hydrocarbon, fluorocarbon, chlorocarbon, fluorochlorocarbon, halogenated hydrocarbon, hydrofluoroolefin, hydrochlorofluoroolefin, CO 2  generating material, or combinations thereof; and at least one of a polyurethane, a polyisocyanurate, or a combination of a polyurethane and a polyisocyanurate. 
   
   
       7 . The method of  claim 1  wherein the adhesive composition comprises a blowing agent comprising water, organic acids that produce CO 2 , hydrocarbons; ethers, halogenated ethers; pentafluorobutane; pentafluoropropane; hexafluoropropane; heptafluoropropane; trifluoropropene; tetrafluoropropene; pentafluoropropene; chlorotrifluoropropene; trans1,2 dichloroethylene, methyl formate or combinations thereof; and at least one of a polyurethane, a polyisocyanurate, or a combination of a polyurethane and a polyisocyanurate. 
   
   
       8 . The method of  claim 1  wherein the adhesive composition comprises a blowing agent comprising 1-chloro-1,2,2,2-tetrafluoroethane; 1,1-dichloro-1-fluoroethane; 1,1,1,2-tetrafluoroethane; 1,1,1,2-tetrafluoroethane; 1-chloro 1,1-difluoroethane; 1,1,1,3,3-pentafluorobutane; 1,1,1,2,3,3,3-heptafluoropropane; trichlorofluoromethane, dichlorodifluoromethane; 1,1,1,3,3,3-hexafluoropropane; 1,1,1,2,3,3-hexafluoropropane; difluoromethane; difluoroethane; 1,1,1,3,3-pentafluoropropane; 1,1,1,3-tetrafluoropropene; trans-1,1,1,3-tetrafluoropropene; 1,1,1,2-tetrafluoropropene; 1,1,1,2,3-pentafluoropropene; 1-chloro-3,3,3-trifluoropropene, or combinations thereof; and at least one of a polyurethane, a polyisocyanurate, or a combination of a polyurethane and a polyisocyanurate. 
   
   
       9 . The method of  claim 1  wherein the adhesive composition comprises a blowing agent comprising 1,1,1,3,3-pentafluorobutane; 1,1,1,3,3-pentafluoropropane or combinations thereof; and at least one of a polyurethane, a polyisocyanurate, or a combination of a polyurethane and a polyisocyanurate. 
   
   
       10 . The method of  claim 1  wherein the adhesive composition comprises a fluorine containing blowing agent, and a mixture of ingredients that react to form at least one of a polyurethane or polyisocyanurate foam, or a combination of a polyurethane and polyisocyanurate foam, in the presence of the blowing agent. 
   
   
       11 . The method of  claim 1  wherein the rigid, closed cell foam is present at a thickness of from about 2.5 cm. to about 15 cm. 
   
   
       12 . A structural member for a roof or an outer wall of a building comprising:
 a) a roof panel or outer wall panel, said roof panel or outer wall panel comprising a plurality of spaced apart beam members, and a sheathing having an inner side and an outer side, the sheathing spanning a space between adjacent beam members and being attached to the beam members such that the inner side of the sheathing is in juxtaposition with the beam members; and   b) a layer of a rigid, closed cell foam comprising a polymer adhesive composition on at least a portion of side walls of said beam members and substantially the entirety of the inner side of the sheathing such that the layer on the sheathing and the beam members is substantially continuous, and adheres the sheathing to the beam members.   
   
   
       13 . The structural member of  claim 12  wherein the beam members are attached to the sheathing by nails, screws, clips, or combinations thereof. 
   
   
       14 . The structural member of  claim 12  wherein the beam members comprise wood, wood composite, metal or combinations thereof. 
   
   
       15 . The structural member of  claim 12  wherein the sheathing comprises wood, oriented strand board, plywood, fibrous cement, fiberglass reinforced gypsum, expanded polystyrene, extruded polystyrene, polyisocyanurate, foam board or combinations thereof. 
   
   
       16 . The structural member of  claim 12  wherein the rigid, closed cell foam comprises a polyurethane, a polyisocyanurate, or combinations thereof. 
   
   
       17 . The structural member of  claim 12  wherein the rigid, closed cell foam is present at a thickness of from about 2.5 cm. to about 15 cm. 
   
   
       18 . The structural member of  claim 12  comprising a roof panel. 
   
   
       19 . The structural member of  claim 12  comprising an outer wall panel 
   
   
       20 . A structural member comprising:
 a) a panel, said panel comprising a plurality of spaced apart beam members, and a sheathing having an inner side and an outer side, the sheathing spanning a space between adjacent beam members and being attached to the beam members such that the inner side of the sheathing is in juxtaposition with the beam members; and   b) a layer of a rigid, closed cell foam comprising a polymer adhesive composition on at least a portion of side walls of said beam members and substantially the entirety of the inner side of the sheathing such that the layer on the sheathing and the beam members is substantially continuous, and adheres the sheathing to the beam members.   
   
   
       21 . The structural member of  claim 20  wherein the beam members are attached to the sheathing by nails, screws, clips, or combinations thereof. 
   
   
       22 . The structural member of  claim 20  wherein the beam members comprise wood, wood composite or metal. 
   
   
       23 . The structural member of  claim 20  wherein the sheathing comprises wood, oriented strand board, plywood, fibrous cement, fiberglass reinforced gypsum, expanded polystyrene, extruded polystyrene, polyisocyanurate, foam board or combinations thereof. 
   
   
       24 . The structural member of  claim 20  wherein the rigid, closed cell foam comprises a polyurethane, a polyisocyanurate, or combinations thereof. 
   
   
       25 . The structural member of  claim 20  wherein the rigid, closed cell foam is present at a thickness of from about 2.5 cm. to about 15 cm. 
   
   
       26 . A structural member comprising:
 a) a panel, said panel comprising a plurality of spaced apart beam members, and a sheathing having an inner side and an outer side, the sheathing spanning a space between adjacent beam members and being attached to the beam members such that the inner side of the sheathing is in juxtaposition with the beam members;   b) an elongated channel for the passage of ventilating air fixed on the inner side of the sheathing between and separated from adjacent spaced apart beam members, and   b) a layer of a rigid, closed cell foam comprising a polymer adhesive composition on at least a portion of side walls of said beam members, on the elongated channel, and substantially the entirety of on the inner side of the sheathing between the elongated channel and the spaced apart beam members, such that the layer of rigid, closed cell foam on the sheathing, the elongated channel and the beam members is substantially continuous, and adheres the sheathing to the beam members.