Fire resistant composite boards and methods

Patent metadata

Field	Value
Publication number	US-9605433-B2
Application number	US-201213672746-A
Country	US
Kind code	B2
Filing date	Nov 9, 2012
Priority date	Nov 9, 2012
Publication date	Mar 28, 2017
Grant date	Mar 28, 2017

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 perlite roofing board;
a mineral based material coating applied as a continuous layer on one or more major surfaces of the perlite roofing board, the mineral based material coating having a coating weight of at least 0.10 lbs/ft 2 , wherein the coating comprises between about 25% and 50% water and between about 50% and 75% of a composition of solid materials, and wherein 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
a glass mat facer adhesively coupled with a first major surface of the one or more major surfaces, the first major surface being coated with the mineral based material coating.

2. A roofing system comprising:
two or more roof deck boards forming at least one joint;
a roofing board positioned over the at least one joint, the roofing board comprising between about 40% and 70% expanded perlite, between about 30% and 60% recycled paper products, between about 1.5% and 10% starch binder, and between about 1% and 5% asphalt;
a mineral based material coating applied as a continuous layer on one or more major surfaces of the roofing board, the mineral based material coating having a coating weight of at least 0.10 lbs/ft2, wherein the coating comprises between about 25% and 50% water and between about 50% and 75% of a composition of solid materials, and wherein 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 wherein the coating limits air flow through the roofing board, providing a barrier to prevent a flame from penetrating the at least one joint; and
a glass mat facer coupled with a first major surface of the one or more major surfaces, the first major surface being coated with the mineral based material coating; and
an adhesive that adheres the roofing board to the glass mat facer.

3. The roofing system of claim 2 , wherein a second major surface opposite the first major surface of the roofing board does not include a fiber mat facer.

4. The roofing system of claim 2 , wherein the mineral based material coating is also applied to the glass mat facer.

5. The roofing system of claim 4 , wherein the glass mat facer comprises a first glass mat facer, wherein the roofing board comprises a second glass mat facer applied on a second major surface opposite the first major surface of the roofing board, wherein the mineral based material coating is also applied to the second glass mat facer.

6. The roofing system of claim 5 , wherein the first glass mat facer comprises a first glass mat weight, and where the second glass mat facer comprises a second glass mat weight less than the first glass mat weight.

7. The roofing system of claim 4 , wherein the glass mat facer has a weight of at least 1.4 lbs/100 ft2.

8. The roofing system of claim 7 , wherein the mineral based material coating has a coating weight of between about 0.18 lbs/ft2 and about 0.21 lbs/ft2.

9. The roofing system of claim 2 , wherein the coating is approximately 100% solids after drying.

10. The roofing system of claim 9 , wherein the composition of solid materials further comprises a filler material.

11. The roofing system of claim 9 , wherein the filler material comprises: clay, mica, talc, expanded perlite fines, flumed silica, fly ash, fiber glass, vermiculite, titanium dioxide, or zinc oxide.

12. The roofing system of claim 2 , wherein the mineral based material coating has a coating weight of at least 0.14 lbs/ft 2 .

13. The roofing system of claim 2 , wherein the mineral based material coating further comprises an acrylic binder.

14. The roofing system of claim 2 , wherein the roofing board does not include a fire retardant.

15. The roofing system of claim 2 , wherein the roofing board is between about ¼ inch thick and 6 inches thick.

16. The roofing system of claim 15 , wherein the roofing board comprises a density between about 1.5 lb/ft 3 and about 12 lbs/ft 3 .

17. A method of manufacturing a roofing system comprising:
positioning two or more roof deck boards such that they form at least one joint;
positioning a roofing board over the at least one joint, the roofing board comprising between about 40% and 70% expanded perlite, between about 30% and 60% recycled paper products, between about 1.5% and 10% starch binder, and between about 1% and 5% asphalt,
applying a mineral based material as a continuous layer to at least one major surface of the roofing board, wherein the coating comprises between about 25% and 50% water and between about 50% and 75% of a composition of solid materials, and wherein 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 wherein the coating limits air flow through the roofing board, providing a barrier to prevent a flame from penetrating the at least one joint,
coupling a glass mat facer with the at least one major surface with an adhesive such that the at least one major surface is faced with the glass mat facer.

18. The method of claim 17 , further comprising:
applying the mineral based material to the faced glass mat surface of the roofing board.

19. The method of claim 18 , 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/ft2.

20. The method of claim 19 , wherein the faced glass mat comprising the coating weight of at least 0.10 lbs/ft 2 faces a roof deck.

Assignees

• Johns Manville

Inventors

• Paradis Duane
• Zheng Guodong

Classifications

• B32B2419/06

  Roofs, roof membranes · CPC title

• E04D5/10

  by making use of compounded or laminated materials, e.g. metal foils or plastic films coated with bitumen · CPC title

• B32B5/18

  characterised by features of a layer {of} foamed material · CPC title

• E04B1/942

  slab-shaped · CPC title

• B32B5/022

  Non-woven fabric · CPC title