Fire resistant composite boards and methods

Patent metadata

Field	Value
Publication number	US-2017191270-A1
Application number	US-201715442811-A
Country	US
Kind code	A1
Filing date	Feb 27, 2017
Priority date	Nov 9, 2012
Publication date	Jul 6, 2017
Grant date	—

Abstract

Embodiments of the invention provide roofing boards and roofing systems having improved fire resistance properties and methods related to the same. According to one aspect, a roofing system is provided. The roofing system includes roofing panels positioned atop structural support members to form a roof deck. Roofing boards are positioned atop the roof deck and coupled thereto and a roofing membrane is positioned atop the roofing boards and coupled therewith. The roofing boards include a coating of a mineral based material applied to one or more surfaces in an amount between the range of about 0.10 lbs/ft 2 and about 0.70 lbs/ft 2 . The mineral based material coating enables the roofing boards to pass the UL 790 class A tests, such as the burning brand test.

First claim

What is claimed is:

1 . A roofing system comprising:
a roofing board; and a mineral based material coating applied to one or more major surfaces of the roofing board, the mineral based material coating being applied in an amount between the range of about 0.05 lbs/ft 2 and about 0.70 lbs/ft 2 .

2 . The roofing system of claim 1 , wherein:
the roofing board comprises one or more of the following materials:
wood fibers;
perlite;
polyisocyanurate;
polystyrene;
extruded polystyrene;
cellular glass; or
gypsum.

3 . The roofing system of claim 1 , wherein:
the roofing board comprises a foam core sandwiched between two nonwoven facer material layers.

4 . The roofing system of claim 1 , further comprising:
a roofing membrane configured to be positioned atop the roofing board and coupled therewith.

5 . The roofing system of claim 4 , wherein the roofing membrane comprises one or more of:
polyvinyl chloride (PVC); thermoplastic polyolefin (TPO); ethylene propylene diene monomer rubber (EPDM); or bitumen.

6 . The roofing system of claim 1 , further comprising:
a roof deck, wherein the roofing board is configured to be positioned atop the roof deck and coupled therewith.

7 . The roofing system of claim 1 , further comprising:
a glass fiber mat coupled with a major surface of the roofing board, the glass fiber mat being saturated with the mineral based material coating.

8 . The roofing system of claim 1 , wherein the roofing board comprises:
a composite core material comprising:
between 40% and 70% of expanded perlite;
between 30% and 60% of paper products;
between 1.5% and 10% of a starch binder; and
between 1.0% and 5% asphalt.

9 . The roofing system of claim 8 , wherein the roofing board further comprises:
a glass mat facer coupled with one surface of the composite core, the glass mat facer having a mat weight of between about 0.9 and 3.0 lbs/100 ft 2 .

10 . The roofing system of claim 1 , wherein:
the mineral based material coating comprises between about 25% and 50% water and between about 50% and 75% of a composition of solid materials; the solid materials comprise between about 44% and 94% calcium carbonate, between about 5% and 10% sodium silicate, and between about 1% and 5% of latex; and the coating limits air flow through the roofing board, thus enabling the roofing board to pass the UL 790 class A tests.

11 . A method of manufacturing a roofing board comprising:
providing a roofing board, applying a mineral based material to at least one major surface of the roofing board, the mineral based material being applied such that the roofing board comprises a coating weight of between about 0.05 lbs/ft 2 and about 0.70lbs/ft 2 .

12 . The method of manufacturing a roofing board of claim 11 , further comprising:
securing a roofing membrane to the roofing board.

13 . The method of manufacturing a roofing board of claim 11 , further comprising:
coupling a glass mat to at least one major surface of the roofing board using an adhesive such that the at least one major surface is faced with the glass mat; and

14 . The method of manufacturing a roofing board of claim 13 , further comprising:
applying the mineral based material to the faced glass mat surface of the roofing board.

15 . The method of manufacturing a roofing board of claim 13 , further comprising:
applying a second glass mat to the other major surface of the roofing board such that both major surfaces of the roofing board are faced with a glass mat; and applying a coating to the other faced glass mat surface of the roofing board, the coating being applied so as to comprise a coating weight of less than 0.10 lbs/ft 2 .

16 . The method of manufacturing a roofing board of claim 14 , wherein:
the faced glass mat comprising the coating weight of at least 0.10 lbs/ft 2 faces a roof deck.

17 . The method of manufacturing a roofing board of claim 11 , wherein:
the mineral based material comprises between about 25% and 50% water and between about 50% and 75% of a composition of solid materials, and wherein the coating is approximately 100% solids after drying.

18 . The method of manufacturing a roofing board of claim 11 , wherein:
the solid materials comprise one or more of calcium carbonate, clay, perlite, fiber glass, silica, fly ash, ceramic spheres, cement, vermiculite, titanium dioxide, zinc oxide, or gypsum.

19 . The method of manufacturing a roofing board of claim 11 , wherein the roofing board comprises:
a composite core material comprising:
between 40% and 70% of expanded perlite;
between 30% and 60% of paper products;
between 1.5% and 10% of a starch binder; and
between 1.0% and 5% asphalt.

20 . The method of manufacturing a roofing board of claim 11 , wherein:
the roofing board comprises a foam core sandwiched between two nonwoven facer material layers.

21 . A roofing system comprising:
a roofing board; and a mineral based material coating applied to one or more major surfaces of the roofing board, wherein:
the mineral based material coating comprises between about 25% and 50% water and between about 50% and 75% of a composition of solid materials;
the solid materials comprise between about 44% and 94% calcium carbonate, between about 5% and 10% sodium silicate, and between about 1% and 5% of latex; and
the coating limits air flow through the roofing board, thus enabling the roofing board to pass the UL 790 class A tests.

Assignees

• Johns Manville

Inventors

• Paradis Duane
• Zheng Guodong

Classifications

• B32B37/12

  characterised by using adhesives · CPC title

• B32B37/18

  involving the assembly of discrete sheets or panels only · CPC title

• E04D13/1662 Primary

  Inverted roofs or exteriorly insulated roofs · CPC title

• B32B2262/101

  Glass fibres · CPC title

• B32B2260/044

  Water-setting substance, e.g. concrete, plaster · CPC title