Patent Application
20240392570
The disclosure made in U.S. Provisional Application No. 63/468,299 filed May 23, 2023 is specifically incorporated by reference as if set forth in its entirety.
The present disclosure relates generally to roofing systems and more particularly to roofing systems incorporating a reinforced insulation material configured to provide increased structural, thermal and moisture performance.
Impacts from hail and other debris against a roof can cause significant damage to a roof. Insurers have created specific testing requirements for certifications for hail resistant roofing systems. In particular, for the “Very Severe Hail” (VSH) classification, requirements include the ability to withstand 2-inch ice balls propelled at 152-160 feet per second, resulting in an impact energy of 53-58 ft-lbs. It can be seen that needs exist for roofing systems that can provide resistance to impacts from very severe hail and/or other types or levels of impact resistance such as in accordance with such requirements. The present disclosure addresses these and other related and unrelated issues.
Briefly described, the present disclosure is directed to roofing systems and components thereof, and to methods of forming and installing such roofing systems and components thereof.
According to aspects of the present disclosure, roofing systems and components thereof are provided, which are configured to withstand impacts from objects such as very severe hail striking the roofing systems. In embodiments, the roofing systems can include one or more layers of insulation materials, with at least one of the layers of insulation including a reinforced insulation material, positioned along a roofing substrate or roof deck, and further can include a membrane positioned over the one or more layers of insulation material, but which roofing systems do not include the use of or need for a coverboard as part of the roofing system. For example, coverboards that generally are required for the protection of roofing systems from impacts such as hail (which can include boards constructed of materials such as gypsum, wood fiber, cement, perlite, asphaltic materials, mineral fibers, plywood, or oriented strand boards) are not required for protection of the roofing systems of the present disclosure.
In some embodiments, roofing systems are provided, which can include roofing materials such as a roof deck, a first layer of an insulation material positioned along the roof deck, and a second layer of an impact resistant reinforced insulation material positioned along an upper surface of the first layer. In embodiments, the reinforced insulation material can include a fiber reinforced polymer composite material integrated with substrate that comprises an insulation material (e.g., a polyisocyanurate insulation or other insulation material) configured to form a fiber reinforced polymer composite insulation material with integrated protection against impacts such that a layer of coverboards, e.g., separate protective coverboard sheets or panels positioned over the first and second layers of insulation materials, are not required to provide the roofing systems with resistance to impacts from hail or other objects striking the roofing system.
In addition, in embodiments, a membrane can be applied over an upper surface of the second layer to provide further protections to the roofing system. For example, and without limitation, the membrane can comprise a material configured to provide resistance to weather, including water shedding (e.g., facilitating flowing of water away from the roofing system); water resistance (e.g., resistance to the passage of water flow therethrough); water ponding (e.g., unwanted pooling or collection of water); ultra violet light (UV) resistance, and other selected properties. In embodiments, the membrane can comprise a membrane such as a thermoplastic polyolefin (TPO), an ethylene propylene diene monomer (EPDM), polyvinyl chloride (PVC), or a modified bitumen membrane. In embodiments, the membrane can be applied to the upper surface of the second layer in the field; such as in sheets, or by being rolled out over the upper surface of the second layer. In other embodiments, the membrane can be pre-applied to the upper surface of the reinforced insulation material of the second layer as part of the manufacturing process thereof. In embodiments, the membrane can be adhered to the fiber reinforced composite polymer material of the reinforced insulation material with an adhesive, or can be heat welded thereto.
In some embodiments, a roofing system according to the principles of the present disclosure can include a first layer that can comprise a first insulation material, such as, for example, a polyisocyanurate insulation material, or other insulation material positioned on top of the roof deck. In embodiments, the roofing systems further can include a second layer, which, in embodiments, can include a reinforced insulation material layer. As an example, in some embodiments, the second layer can include a fiber reinforced polymer composite insulation material layer comprising a substrate having a reinforcing sublayer integrated therewith (for example, in embodiments, a glass fiber reinforced polymer composite material layer), wherein the reinforcing sublayer can define an upper surface of the second layer. In embodiments, the substrate can comprise a second insulation material that, in embodiments, can include a polyisocyanurate insulation material or other insulation material. In embodiments, the reinforcing sublayer can comprise a fiber reinforced composite polymer material formed as a facer or skin applied to an upper surface of the substrate.
In addition, in embodiments, the first insulation material of the first layer can be formed with an increased thickness. For example, in embodiments, the first layer can comprise a first insulation material having a thickness of approximately 1 inch to approximately 3.6 inches, which can help provide enhanced insulation properties for the roofing system. In some embodiments, the roofing system can include a third layer of insulation material that can be positioned along an upper surface of the first layer or arranged between the first and second layers of insulation material. In embodiments, the roofing system can include a plurality of sections, with the third layer being configured to increase the thickness of the first insulation material to help increase the insulation properties of the roofing system.
In embodiments, the roofing system further includes a membrane attached to the reinforcing sublayer of the second layer. In embodiments, the membrane can be configured to provide weather resistance and various other properties to the roofing system, for example and without limitation, water shedding (e.g., facilitating flowing of water away from the roofing system); water resistance (e.g., resistance to the passage of water flow therethrough); water ponding (e.g., unwanted pooling or collection of water); ultra violet light (UV) resistance, and other selected properties.
In some embodiments, the membrane can be attached to the reinforced insulation material, such by an adhesive, by heat welding, or otherwise being bonded to the fiber reinforced polymer composite material to provide weather resistance properties. In some embodiments, the membrane can be applied over the reinforced insulation material in the field a part of a method of forming a roof; while in other embodiments, the membrane can be attached to the reinforced insulation panels as part of the manufacture thereof, such that the reinforced insulation panels can be formed with integrated impact protection functionality to resist cracking and provide protection against impacts, and with a weather resistant upper surface to facilitate installation of the roofing system without requiring a coverboard as is required in conventional roof structures.
In embodiments, a roofing system formed or installed according to the principles of the present disclosure can include a roof deck, first and second layers of insulation material applied over the roof deck, and a membrane positioned over the upper surface of the second later of insulation, wherein the roofing system is configured to meet or exceed requirements for Very Severe Hail Resistance according to ANSI FM 4473 VSH Impact Resistance Testing Standard for Impact Resistance Testing of Rigid Roofing Materials by Impacting with Freezer Ice Balls (FM 4473). In addition, in embodiments, other test methods can be used, such as, for example, FM 4470 VSH Impact Resistance Testing Standard for Single-Ply, Polymer-Modified Bitumen Sheet, Built-Up Roof (BUR) and Liquid Applied Roof Assemblies (FM 4470). The disclosed roofing systems can meet or exceed these requirements without requiring the inclusion of a coverboard for protection against impacts from hail, including very severe hail. In addition, in embodiments, the roofing system can be configured to provide a resistance to conductive heat flow through the roofing system having an R-value of at least R30, such that the roofing system has an overall resistance to conductive heat flow that is substantially equal to or greater than an overall resistance to conductive heat flow through a conventional roofing system including a coverboard, without a substantial difference in thickness of the roofing system versus such a roofing system including a coverboard.
Various aspects of roofing systems and components of roofing systems can include, in embodiments, a plurality of layers of insulation materials secured along a roof deck, at least one of the layers of insulation materials including a reinforced insulation material comprising an insulation material having a reinforcing sublayer that comprises a fiber reinforced polymer composite material integrated therewith.
According to one aspect, a roofing system is provided, the roofing system comprising a roof deck; a first layer positioned above the roof deck, the first layer comprising a first insulation material; a second layer positioned above the first layer, the second layer comprising a substrate comprising a second insulation material; and a reinforcing sublayer laminated to, attached to, extruded with, or molded with the substrate so as to be integrated with the substrate, the reinforcing sublayer comprising a fiber reinforced polymer composite material and defining an upper surface of the second layer opposite the first layer; and a membrane positioned above the upper surface of the second layer; wherein the roofing system does not include a coverboard between the roof deck and the membrane.
In embodiments, the roofing system further comprises an adhesive material applied between the membrane and the upper surface of the second layer and configured to attach the membrane to the fiber reinforced polymer composite material of the second layer.
In some embodiments, second layer further comprises an adhesive material applied between the substrate and the fiber reinforced polymer composite material of the reinforcing sublayer. In embodiments, the adhesive material comprises isocyanate terminated urethane polymers, methacrylate's, butyl-based adhesives, polymer modified asphaltic materials, polyurethane foams, rubber contact adhesives, or combinations thereof.
In embodiments of the roofing system, the second layer is configured to provide a resistance cracking upon impact of an object thereagainst such that the roofing system exceeds requirements for Very Severe Hail Resistance according to FM 4473 VSH Impact Resistance Testing Standard for Impact Resistance Testing of Rigid Roofing Materials by Impacting with Freezer Ice Balls.
In embodiments of the roofing system, the fiber reinforced polymer composite material comprises a plurality of glass fibers, fiberglass fibers, carbon fibers, natural fibers, or a combination thereof, and a resin.
In embodiments of the roofing system. the resin comprises a polymer, a biodegradable material, low-carbon footprint material, or a combination thereof.
In embodiments of the roofing system, the fiber reinforced polymer composite material comprises a thickness of 1 mm to 8 mm.
In embodiments of the roofing system, the fiber reinforced polymer composite material comprises a sheet formed by molding a plurality of fibers with a sheet molding compound.
In embodiments of the roofing system, the fiber reinforced polymer composite material comprises a sheet formed by a pultrusion process and including a resin and a plurality of substantially continuous fibers.
In embodiments the roofing system further comprise a layer of a vapor retardant material positioned between the roof deck and the first insulation layer.
In embodiments of the roofing system, the membrane comprises a two-ply modified bitumen material including a base sheet comprising a bituminous asphalt material and a cap sheet comprising a polymeric material applied over the base sheet.
In embodiments of the roofing system, the membrane comprises at least one of a thermoplastic polyolefin, an ethylene propylene diene monomer, polyvinyl chloride, or a modified bitumen material.
In embodiments of the roofing system, the first insulation material and the second insulation material each comprise polyisocyanurate, mineral wool, expanded polystyrene foam, extruded polystyrene foam, or a combination thereof.
In embodiments of the roofing system, the first insulation layer and the second insulation layer each comprise a thickness of 2 inches to 3.6 inches.
In embodiments, the roofing system further comprises a third insulation layer attached to the first insulation layer, the third insulation layer having a thickness of less than 2 inches.
In embodiments of the roofing system, the first layer comprises a thickness of 1 inch to 3.65 inches; and the second layer comprises a thickness of 1 inch to 3.75 inches.
In embodiments of the roofing system, the first insulation layer and the second insulation layer together are configured to provide a resistance to conductive heat flow through the roofing system having an R-value of at least R30; and further comprising a third insulation layer comprising an additional insulation material positioned along the first insulation layer; wherein the third insulation layer is configured to increase the resistance to conductive heat flow of the roofing system such that the roofing system has an overall resistance to conductive heat flow that is equal to or greater than an overall resistance to conductive heat flow of a roofing system including a coverboard.
In embodiments, the roofing system further comprises an additional reinforcing sublayer attached to a lower surface of the substrate; wherein the additional reinforcing sublayer comprises a fiber reinforced material that is different from the fiber reinforced polymer composite material positioned along the upper surface of the substrate.
In embodiments of the roofing system, the first insulation layer has a first thickness, and the second insulation layer has a second thickness that is greater than the first thickness of the first insulation layer; and wherein the roofing system has a thickness substantially equal to or less than a thickness of a roofing system including a coverboard.
In embodiments, the roofing system further comprises at least one sensor coupled to the second insulation layer.
In embodiments of the roofing system, the membrane comprises a polymeric sheet configured to resist migration of water therethrough.
According to another aspect, a package is provided, the package comprising a plurality of reinforced insulation panels; wherein each of the reinforced insulation panels comprises a substrate; and a reinforcing sublayer laminated to, attached to, extruded with or molded with the substrate so as to be integrated with the substrate, the reinforcing sublayer comprising a fiber reinforced polymer composite material and defining an upper surface of each reinforced insulation panel; wherein the reinforced insulation panels are configured to provide a resistance to cracking upon impact of an object thereagainst such that when the reinforced insulation panels are included as part of a roofing system having a first layer of insulation panels positioned along a roof deck, a second layer of the reinforced insulation panels above the first layer of insulation panels, a membrane on top of the upper surfaces of the reinforced insulation panels, and without a coverboard positioned between the membrane and the insulation panels, the roofing system exceeds requirements for Very Severe Hail Resistance according to FM 4473 VSH Impact Resistance Testing Standard for Impact Resistance Testing of Rigid Roofing Materials by Impacting with Freezer Ice Balls.
In embodiments of the package, the reinforced insulation panels further comprise an additional reinforcing sublayer attached to a lower surface of the substrate; wherein the additional reinforcing sublayer comprises a fiber reinforced material that is different from the fiber reinforced polymer composite material positioned along the upper surface of the substrate.
In embodiments of the package, the reinforced insulation panels each further comprise a membrane attached to an upper surface thereof; wherein the membrane comprises a two-ply modified bitumen material including base sheet attached to the fiber reinforced polymer composite material and comprising a bituminous asphalt material, and a cap sheet applied over the base sheet and comprising a weather resistant polymeric material.
In embodiments of the package, the reinforced insulation panels each comprise a thickness of 2 inches to 3.75 inches.
In embodiments of the package, the substrate comprises polyisocyanurate, mineral wool, expanded polystyrene foam, extruded polystyrene foam, or a combination thereof.
In embodiments of the package, the fiber reinforced polymer composite material comprises a plurality of glass fibers, fiberglass fibers, carbon fibers, natural fibers, or a combination thereof, and a resin molded or extruded to form the fiber reinforced material.
In embodiments of the package, the resin comprises a polymer, a biodegradable material, low-carbon footprint material, or a combination thereof.
In embodiments of the package, the fiber reinforced polymer composite material comprises a thickness of 1 mm to 8 mm.
In embodiments, the package further comprises a plurality of insulation panels comprising a first insulation material and configured without a fiber reinforcing polymer composite material positioned along an upper surface thereof.
In some embodiments, the first insulation material comprises polyisocyanurate, mineral wool, expanded polystyrene foam, extruded polystyrene foam, or a combination thereof.
In embodiments of the package, the insulation panels and the reinforced insulation panels together are configured to provide a resistance to conductive heat flow through the roofing system having an R value of at least R30.
According to another aspect, a method of forming a roofing system comprises positioning a first layer along a roof deck; wherein the first layer comprises a first insulation material and has a lower surface facing the roof deck and an upper surface; positioning a second layer over the upper surface of the first insulation layer; wherein the second layer comprises a second insulation material including a substrate; and a reinforcing sublayer laminated to, attached to, extruded with or molded with the substrate so as to be integrated with the substrate, the reinforcing sublayer comprising a fiber reinforced polymer composite material and defining an upper surface of the second layer opposite the first layer; positioning a membrane over the second insulation layer; wherein the roofing system does not include a coverboard between the roof deck and the membrane.
In embodiments, the method further comprises positioning a layer of a vapor retardant material along the roof deck prior to positioning the first insulation layer on the roof deck.
In embodiments, the method further comprises applying an adhesive between the fiber reinforced polymer composite material of the second insulation layer and the membrane; wherein the adhesive is configured to attach the membrane to the fiber reinforced polymer composite material.
In some embodiments, the adhesive material can include isocyanate terminated urethane polymers, methacrylate's, butyl-based adhesives, polymer modified asphaltic materials, polyurethane foams, rubber contact adhesives, or combinations thereof.
In some embodiments, the method further comprises applying heat to the membrane after positioning the membrane over the second insulation layer to attach the membrane to the second insulation layer.
In embodiments, the method further comprises positioning a third layer along an upper surface of the roof deck, and attaching the lower surface of the first layer to the upper surface of the third layer; wherein the third layer comprises an insulation material.
In embodiments of the method, the first layer and the second layer together are configured to provide a resistance to conductive heat flow through the roofing system having an R value of at least R30.
According to still another aspect, a roofing system comprises a roof deck; at least two first insulation panels positioned above the roof deck, each of the first insulation panels comprising a first insulation material; at least two second insulation panels positioned above the first insulation panels, each of the second insulation panels comprising a second insulation material; wherein the second insulation material comprises a substrate, and a reinforcing sublayer laminated to, attached to, extruded with or molded with the substrate so as to be integrated with the substrate, the reinforcing sublayer comprising a fiber reinforced polymer composite material and defining an upper surface of the each of the second insulation panels; and a membrane positioned above the second insulation panels; wherein the roofing system does not include a coverboard between the roof deck and the membrane.
In embodiments of the roofing system, the second insulation panels are configured to provide a resistance to cracking upon impact of an object thereagainst such that the roofing system exceeds requirements for Very Severe Hail Resistance according to FM 4473.
In embodiments, the roofing system further comprises a layer of a vapor retardant material positioned between the roof deck and the first insulation panels.
In embodiments, the roofing system further comprises an adhesive material applied to the upper surfaces of the second insulation panels and configured to attach the membrane to the upper surfaces of the second insulation panels.
In some embodiments, second insulation material further comprises an adhesive material attaching the substrate to the fiber reinforced polymer composite material; wherein, in embodiments, the adhesive material comprises isocyanate terminated urethane polymers, methacrylate's, butyl-based adhesives, polymer modified asphaltic materials, polyurethane foams, rubber contact adhesives, or combinations thereof.
In embodiments, the roofing system further comprises an additional reinforcing sublayer attached to a lower surface of the substrate; wherein the additional reinforcing sublayer comprises a fiber reinforced material that is different from the fiber reinforced polymer composite material positioned along the upper surface of the substrate.
In embodiments of the roofing system, the substrate of the second insulation material comprises polyisocyanurate, mineral wool, expanded polystyrene foam, extruded polystyrene foam, or a combination thereof.
According to a further aspect, a package is provided, the package comprising a plurality of insulation panels including reinforced insulation panels each comprising a substrate comprising an insulation material, and a reinforcing sublayer laminated to, attached to, extruded with or molded with the substrate so as to be integrated with the substrate; wherein the reinforcing sublayer comprises a fiber reinforced polymer composite material; and a membrane comprising at least one of a thermoplastic polyolefin, an ethylene propylene diene monomer, polyvinyl chloride, or a modified bitumen sheet including a base sheet comprising a bituminous asphalt material and a cap sheet comprising polymeric materials or a combination thereof; wherein the reinforced insulation panels are configured to provide a resistance to cracking upon impact of an object thereagainst such that when the reinforced insulation panels are included as part of a roofing system without a coverboard, the roofing system exceeds requirements for Very Severe Hail Resistance according to FM 4473 VSH Impact Resistance Testing Standard for Impact Resistance Testing of Rigid Roofing Materials by Impacting with Freezer Ice Balls.
In embodiments, the reinforced insulation panels further comprise an additional reinforcing sublayer attached to a lower surface of the substrate; wherein the additional reinforcing sublayer comprises a fiber reinforced material that is different from the fiber reinforced polymer composite material positioned along an upper surface of the substrate.
In embodiments, the reinforced insulation panels each further comprise a membrane attached to an upper surface thereof; wherein the membrane comprises a two-ply modified bitumen material including base sheet attached to the fiber reinforced polymer composite material and comprising a bituminous asphalt material, and a cap sheet applied over the base sheet and comprising a weather resistant polymeric material.
In some embodiments, the reinforced insulation panels each comprise a thickness of 2 inches to 3.75 inches.
In some embodiments, the substrate comprises polyisocyanurate, mineral wool, expanded polystyrene foam, extruded polystyrene foam, or a combination thereof.
In some embodiments, the fiber reinforced polymer composite material comprises a plurality of glass fibers, fiberglass fibers, carbon fibers, natural fibers, or a combination thereof, and a resin molded or extruded to form the fiber reinforced material.
In embodiments, the resin comprises a polymer, a biodegradable material, low-carbon footprint material, or a combination thereof.
In embodiments, the fiber reinforced polymer composite material comprises a thickness of 1 mm to 8 mm.
In embodiments, the package further comprises a plurality of insulation panels comprising an insulation material including polyisocyanurate, mineral wool, expanded polystyrene foam, extruded polystyrene foam, or a combination thereof and configured without a fiber reinforcing polymer composite material positioned along an upper surface thereof.
In embodiments of the package, the insulation panels and the reinforced insulation panels together are configured to provide a resistance to conductive heat flow through the roofing system having an R value of at least R30.
In some embodiments, the package further comprises an adhesive material adapted to attach the membrane to the fiber reinforced polymer composite material of the reinforced insulation panels.
According to another aspect, a method is provided, the method comprising mixing a plurality of reinforcing fibers with a resin or sheet molding compound to form a mixture; wherein the reinforcing fibers include glass fibers, fiberglass fibers, carbon fibers, natural fibers or combinations thereof; forming the mixture into a fiber reinforced polymer composite sheet; moving the fiber reinforced polymer composite sheet along a path of travel; and attaching an insulation material to a first surface of the fiber reinforced polymer composite sheet such that the fiber reinforced polymer composite sheet is integrated with the insulation material to form a fiber reinforced polymer composite insulation material; wherein the fiber reinforced polymer composite insulation material is configured to provide a resistance to cracking upon impact of an object thereagainst such that when the fiber reinforced polymer composite insulation material is included as part of a roofing system with a first layer of an insulation material and a membrane, and without a coverboard, the roofing system exceeds requirements for Very Severe Hail Resistance according to FM 4473 VSH Impact Resistance Testing Standard for Impact Resistance Testing of Rigid Roofing Materials by Impacting with Freezer Ice Balls.
In embodiments, the method further comprises applying a modified bitumen sheet to a second side of the fiber reinforced polymer composite sheet.
In embodiments, attaching an insulation material to the first surface of the fiber reinforced polymer composite sheet comprises depositing a foam mixture including polyisocyanurate and at least one isocyanate reactive compound along the first surface of the fiber reinforced polymer composite sheet, and allowing the foam mixture to expand to form a polyisocyanurate foam; wherein upon expanding, the polyisocyanurate foam is substantially integrated with the fiber reinforced polymer composite sheet.
In embodiments, attaching an insulation material to a first surface of the fiber reinforced polymer composite sheet comprises applying an adhesive material between the insulation material and the fiber reinforced polymer composite sheet, and adhesively attaching the insulation material to the fiber reinforced polymer composite sheet.
In embodiments, forming the mixture into the fiber reinforced polymer composite sheet comprises mixing a plurality of short reinforcing fibers with a sheet molding compound, and pressing the mixture.
In embodiments, forming the mixture into the fiber reinforced polymer composite sheet comprises mixing a continuous stream of reinforcing fibers with a resin.
In embodiments, the method further comprises applying a facer to the insulation material along one side thereof opposite the fiber reinforced polymer composite sheet.
According to another embodiments, a method of forming a roof comprises: positioning a first layer along a roof deck, the first layer including a first insulation material having a lower surface and an upper surface; positioning a second layer over the upper surface of the first insulation layer; wherein the second layer comprises a second insulation material including a substrate, and a reinforcing sublayer laminated to, attached to, extruded with, or molded with the substrate so as to be integrated with the substrate; wherein the reinforcing sublayer comprises a fiber reinforced polymer composite material and defines an upper surface of the second insulation material; applying a membrane over the reinforcing sublayer of the second insulation material; and wherein the second insulation material is configured to provide a resistance cracking upon impact of an object thereagainst such that the roof exceeds requirements for Very Severe Hail Resistance according to FM 4473 VSH Impact Resistance Testing Standard for Impact Resistance Testing of Rigid Roofing Materials by Impacting with Freezer Ice Balls.
In embodiments, the method further comprises positioning a layer of a vapor retardant material along the roof deck prior to positioning the first insulation layer on the roof deck.
In embodiments, the method further comprises applying an adhesive between the reinforcing sublayer of the second insulation layer and the membrane; wherein the adhesive is configured to attach the membrane to the fiber reinforced polymer composite material of the reinforcing sublayer.
In some embodiments, the adhesive material comprises an isocyanate terminated urethane polymers, methacrylate's, butyl-based adhesives, polymer modified asphaltic materials, polyurethane foams, rubber contact adhesives, or combinations thereof.
In some embodiments, the method further comprises applying heat to the membrane after positioning the membrane over the second insulation layer to attach the membrane to the second insulation layer.
In embodiments, the method further comprises applying a third layer comprising an insulation to the first layer.
In embodiments of the method, the first insulation material of the first layer and the second insulation material of the second layer are configured to provide a resistance to conductive heat flow through the roof having an R value of at least R30.
In embodiments of the method, the membrane comprises a modified bitumen sheet; and wherein applying a membrane over the reinforcing sublayer of the second insulation material comprises applying an adhesive between the modified bitumen sheet and the reinforcing sublayer; wherein the adhesive is configured to adhere the reinforcing sublayer of the second insulation material to the modified bitumen sheet.
According to a further aspect, a method comprises forming a mixture of reinforcing fibers and a resin or sheet molding compound, wherein the reinforcing fibers include glass fibers, fiberglass fibers, carbon fibers, natural fibers or combinations thereof; applying the mixture to a first surface of an insulation material to form a fiber reinforced polymer composite insulation panel or sheet comprising a fiber reinforced polymer composite sheet formed from the mixture of the reinforcing fibers and the resin or sheet molding compound integrated with the insulation material; wherein the fiber reinforced polymer composite insulation material is configured to provide a resistance to cracking upon impact of an object thereagainst such that when the fiber reinforced polymer composite insulation material is included as part of a roofing system the roofing system exceeds requirements for Very Severe Hail Resistance according to FM 4473 VSH Impact Resistance Testing Standard for Impact Resistance Testing of Rigid Roofing Materials by Impacting with Freezer Ice Balls.
In embodiments, the method further comprises applying a modified bitumen sheet to a second side of the fiber reinforced polymer composite sheet.
In embodiments of the method, attaching an insulation material to the first surface of the fiber reinforced polymer composite sheet comprises depositing a foam mixture including polyisocyanurate and at least one isocyanate reactive compound along the first surface of the fiber reinforced polymer composite sheet, and allowing the foam mixture to expand to form a polyisocyanurate foam; wherein upon expanding, the polyisocyanurate foam is substantially integrated with the fiber reinforced polymer composite sheet.
In embodiments of the method, attaching an insulation material to a first surface of the fiber reinforced polymer composite sheet comprises applying an adhesive material between the insulation material and the fiber reinforced polymer composite sheet, and attaching the insulation material to the fiber reinforced polymer composite sheet.
In some embodiments, applying the adhesive material can comprise spraying, rolling, extruding, mopping, or combinations thereof, the adhesive material along the first surface of the fiber reinforce composite sheet or along an upper surface of the insulation material.
In embodiments, the adhesive material can include isocyanate terminated urethane polymers, methacrylate's, butyl-based adhesives, polymer modified asphaltic materials, polyurethane foams, rubber contact adhesives, or combinations thereof.
In embodiments of the method, forming the mixture into the fiber reinforced polymer composite sheet comprises mixing a plurality of short reinforcing fibers with a sheet molding compound, and pressing the mixture.
In embodiments of the method, forming the mixture into the fiber reinforced polymer composite sheet comprises mixing a continuous stream of reinforcing fibers with a resin.
In embodiments, the method further comprises applying a facer to the insulation material along one side thereof opposite the fiber reinforced polymer composite sheet.
Accordingly, embodiments of roofing systems, reinforced insulation materials for use in such roofing systems, and methods for forming reinforce insulation materials, and for installing such reinforced insulation materials to a roofing system with enhanced resistance to impacts without including a coverboard as part of the roofing system, which are directed to the above discussed and other needs are disclosed. The foregoing and other advantages and aspects of the embodiments of the present disclosure will become apparent and more readily appreciated from the following detailed description, taken in conjunction with the accompanying drawings. Moreover, it is to be understood that both the foregoing summary of the disclosure and the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the present disclosure.
The accompanying drawings, which are included to provide a further understanding of the embodiments of the present disclosure, are incorporated in and constitute a part of this specification, illustrate embodiments of this disclosure, and together with the detailed description, serve to explain the principles of the embodiments discussed herein. No attempt is made to show structural details of this disclosure in more detail than may be necessary for a fundamental understanding of the exemplary embodiments discussed herein and the various ways in which they may be practiced.
Embodiments of the present disclosure will now be described in more detail with reference to the attached drawing figures.
The present disclosure is directed to roofing systems, methods of installing roofing systems, and to reinforced insulation panels for use in roofing systems as described herein and illustrated in
For a roofing system to achieve certification or classification as a hail resistant roofing system, including to be achieve a “Very Severe Hail” (VSH) certification or classification (Class 4—the most stringent certification), the roofing system and components thereof generally must meet the requirements provided under Factory Mutual (FM)® hail-resistant test method ANSI FM 4473 “Specification test standard for Impact Resistance Testing of Rigid Roofing Materials by Impacting with Freezer Ice Balls” (FM 4473). The FM 4473 testing standard for Very Severe Hail Resistance requires the roofing system withstand up to 2-inch ice balls propelled at 152-160 feet per second, resulting in an impact energy of 53-58 ft. lbs. Withstanding such testing may mean, after impact, the roofing system components will not exhibit cracks, dents, and/or other visible damage.
In addition, in embodiments, other standards and tests may be utilized to classify hail resistant roofing systems and/or components of such roofing systems, such as ASTM D3746 and/or UL 2218. For example, in some embodiments, other testing methods and standards, such as ANSI FM 4470 directed to testing of hail resistance for “Single-Ply, Polymer-Modified Bitumen Sheet, Built-Up Roof (BUR) and Liquid Applied Roof Assemblies for use in Class 1 and Noncombustible Roof Deck Construction” (FM 4470) can be used.
The roofing systems 100 (
In embodiments, roofing systems formed according to the principles of the present disclosure can be used for commercial and residential construction. For example, in embodiments, the roofing systems can be configured to form a low slope roof, including a roof having a slope or pitch of Y/X, where Y corresponds to the “rise” of the roof, and where X corresponds to the “run” of the roof. In embodiments, the roof can have a pitch or slope where Y and X are in a ratio of less 4:12. In some embodiments, Y and X are in a ratio of less than 3:12. In some embodiments, Y and X are in a ratio of less than 2:12. In some embodiments, Y and X are in a ratio of less than 1:12. In some embodiments, Y and X are in a ratio of 1:12 to 3:12.
In other embodiments, the roofing system can be configured to form a roof having a slope of greater than a ratio of 4:12. For example, the roof can have a pitch or slope where Y and X are in a ratio of 4:12 to 12:12. In some embodiments, Y and X are in a ratio of 5:12 to 12:12. In some embodiments, Y and X are in a ratio of 6:12 to 12:12. In some embodiments, Y and X are in a ratio of 7:12 to 12:12. In some embodiments, Y and X are in a ratio of 8:12 to 12:12. In some embodiments, Y and X are in a ratio of 9:12 to 12:12. In some embodiments, Y and X are in a ratio of 10:12 to 12:12. In some embodiments, Y and X are in a ratio of 11:12 to 12:12.
In embodiments, the roof deck 101 can comprise a plurality of rafters or beams (e.g., as indicated at 106 in
In addition, in some embodiments such as indicated in
In embodiments, the first layer 102 of the roofing system 100 can comprise a panel or sheet formed from a first insulation material. For example, in embodiments, the first insulation material can comprise polyisocyanurate, mineral wool, polyurethane, expanded polystyrene foam, extruded polystyrene foam, insulation materials including recycled materials, natural fibers, (such as wood or other fibers), or combinations thereof. In embodiments of a method for forming the roofing system, installation of the roofing system 100, as indicated in
In some embodiments, the first layer 102 can be provided with an expanded thickness configured to provide increased resistance to conductive heating therethrough. For example, a roofing system that includes a ½ inch to ⅝ inch coverboard for impact resistance and insulation properties, can have a resistance to conductive heat flow through the roofing system having an R-value of about R30. In embodiments, the roofing system 100 including the first and second layers 102 and 103 of insulation materials will be configured to provide a resistance to conductive heat flow through the roofing system having an R-value of at least R30, but with the thickness of the overall roofing system substantially matching the thickness of a roofing system having a coverboard positioned between the insulation and a membrane 104.
In embodiments, the first layer 102 can have a thickness of 1 inch to 2.6 inches; and, in embodiments, can have a thickness of 1 inch to 3.75 inches. In other embodiments, the first layer 102 can have a thickness of 1 inch to 3.65 inches, 1 inch to 3.6 inches, 1 inch to 3.5 inches, 1 inch to 3.4 inches, 1 inch to 3.3 inches, 1 inch to 3.2 inches, 1 inch to 3.1 inches, 1 inch to 3 inches, 1 inch to 2.9 inches, 1 inch to 2.8 inches. 1 inch to 2.7 inches, 1 inch to 2.6 inches, 1 inch to 2.5 inches, 1 inch to 2.4 inches, 1 inch to 2.3 inches, 1 inch to 2.2 inches, 1 inch to 2.1 inches, 1 inch to 2 inches, 1 inch to 1.9 inches, 1 inch to 1.8 inches, 1 inch to 1.7 inches, 1 inch to 1.6 inches, 1 inch to 1.5 inches, 1 inch to 1.4 inches, 1 inch to 1.3 inches, 1 inch to 1.2 inches, 1 inch to 1.1 inches.
In other embodiments, the first layer 102 can have a thickness of 1.5 inches to 3.75 inches, 1.5 inches to 3.65 inches, 1.5 inches to 3.6 inches, 1.5 inches to 3.5 inches, 1.5 inches to 3.4 inches, 1.5 inches to 3.3 inches, 1.5 inches to 3.2 inches, 1.5 inches to 3.1 inches, 1.5 inches to 3 inches, 1.5 inches to 2.9 inches, 1.5 inches to 2.8 inches, 1.5 inches to 2.7 inches, 1.5 inches to 2.6 inches, 1.5 inches to 2.5 inches, 1.5 inches to 2.4 inches, 1.5 inches to 2.3 inches, 1.5 inches to 2.2 inches, 1.5 inches to 2.1 inches, 1.5 inches to 2 inches, 1.5 inches to 1.9 inches, 1.5 inches to 1.8 inches, 1.5 inches to 1.7 inches, 1.5 inches to 1.6 inches. In other embodiments, the first layer can have a thickness of 2 inches to 3.75 inches, 2 inches to 3.65 inches, 2 inches to 3.6 inches, 2 inches to 3.5 inches, 2 inches to 3.4 inches, 2 inches to 3.3 inches, 2 inches to 3.2 inches, 2 inches to 3.1 inches, 2 inches to 3 inches, 2 inches to 2.9 inches, 2 inches to 2.8 inches, 2 inches to 2.7 inches, 2 inches to 2.6 inches, 2 inches to 2.5 inches, 2 inches to 2.4 inches, 2 inches to 2.3 inches, 2 inches to 2.2 inches, 2 inches to 2.1 inches.
In some embodiments, the first layer 102 can have a thickness of 2.5 inches to 3.75 inches, 2.5 inches to 3.65 inches, 2.5 inches to 3.6 inches, 2.5 inches to 3.5 inches, 2.5 inches to 3.4 inches, 2.5 inches to 3.3 inches, 2.5 inches to 3.2 inches, 2.5 inches to 3.1 inches, 2.5 inches to 3 inches, 2.5 inches to 2.9 inches, 2.5 inches to 2.8 inches, 2.5 inches to 2.7 inches, 2.5 inches to 2.6 inches. In addition, in embodiments, the first layer can have a thickness of 3 inches to 3.75 inches, 3 inches to 3.65 inches, 3 inches to 3.6 inches, 3 inches to 3.5 inches, 3 inches to 3.4 inches, 3 inches to 3.3 inches, 3 inches to 3.2 inches, or 3 inches to 3.1 inches. Other thicknesses also can be provided.
In other embodiments, the roofing system 100 can include an additional or third layer of an insulation material, such as indicated at 108 in
By way of example, in embodiments, the first layer 102 can have a thickness of, for example, 1 inch to 3.25 inches and an additional or third layer 108 of an insulation materials can be applied thereover, with the additional or third layer 108 having a thickness of about 0.5 inches so as to increase the total thickness of the insulation material provided by the first layer to 3-3.75 inches. In other embodiments, the additional or third layer 108 can have a thickness of 0.1 to 1 inches, 0.1 to 0.9 inches, 0.1 to 0.8 inches, 0.1 to 0.7 inches, 0.1 to 0.6 inches, 0.1 to 0.5 inches, 0.1 to 0.4 inches, 0.1 to 0.3 inches, 0.1 to 0.2 inches, 0.2 inch to 1 inch, 0.2 inch to 0.9 inch, 0.2 inch to 0.8 inch, 0.2 inch to 0.7 inch, 0.2 inch to 0.6 inch, 0.2 inch to 0.5 inch, 0.2 to 0.4 inch, 0.2 inch to 0.3 inch, 0.3 to 1 inch, 0.3 inch to 0.9 inch, 0.3 inch to 0.8 inch, 0.3 inch to 0.7 inch, 0.3 inch to 0.6 inch, 0.3 inch to 0.5 inch, 0.3 inch to 0.4 inch. Other thicknesses of such an additional or third layer also can be provided.
In addition, in some embodiments, the third layer 108 can be integrated with the first layer, such as being formed with or laminated to the first layer during manufacture of the first layer. In other embodiments, the third layer 108 can be separately adhered to the first layer 102, such as with an adhesive materials, e.g., during manufacture of the first layer, or in the field as part of the installation of the roofing system 100.
As further illustrated in
In embodiments, the membrane 104 can comprise a thermoplastic polyolefin (TPO), an ethylene propylene diene monomer (EPDM), or a polyvinyl chloride (PVC) membrane including a single ply sheet material having a thickness of 20 mils to 120 mils and in some embodiments, a thickness of 20 mils to 110 mils, 20 mils to 100 mils, 20 mils to 90 mils, 20 mils to 80 mils, 20 mils to 70 mils, 20 mils to 60 mils, 20 mils to 50 mils, 20 mils to 40 mils, 20 mils to 30 mils, 30 mils to 120 mils, 30 mils to 110 mils, 30 mils to 100 mils, 30 mils to 90 mils, 30 mils to 80 mils, 30 mils to 70 mils, 30 mils to 60 mils, 30 mils to 50 mils, 30 mils to 40 mils, 40 mils to 120 mils, 40 mils to 110 mils, 40 mils to 100 mils, 40 mils to 90 mils, 40 mils to 80 mils, 40 mils to 70 mils, 40 mils to 60 mils, 40 mils to 50 mils, 50 mils to 120 mils, 50 mils to 110 mils, 50 mils to 100 mils, 50 mils to 90 mils, 50 mils to 80 mils, 50 mils to 70 mils, 50 mils to 60 mils, 60 mils to 120 mils, 60 mils to 110 mils, 60 mils to 100 mils, 60 mils to 90 mils, 60 mils to 80 mils, 60 mils to 70 mils, 70 mils to 120 mils, 70 mils to 110 mils, 70 mils to 100 mils, 70 mils to 90 mils, 70 mils to 80 mils, 80 mils to 120 mils, 80 mils to 110 mils, 80 mils to 100 mils, 80 mils to 90 mils, 90 mils to 120 mils, 90 mils to 110 mils, 90 mils to 100 mils, 100 mils to 120 mils 100 mils to 110 mils, or 110 mils to 120 mils. Other thicknesses of the membrane also can be used.
In addition, in embodiments, the membrane 104 can comprise a fleece backed TPO membrane, or a TPO membrane with a TPO or PVC adhesive attached EPDM silicone layer or other cushioning material configured to help absorb impacts from hail or other objects striking the upper surface of the membrane. In embodiments, the membrane 104 will define an upper, exposed surface 110 of the roofing system 100, configured to withstand exposure to weather (e.g., withstand exposure to sun, wind, rain, snow, extreme temperatures, extreme cold). In some embodiments, the upper surface of the membrane can be further coated with, for example, an asphalt material, and a covering material such as a plurality of granules applied thereto.
In still other embodiments, the membrane 104 can comprise a modified bitumen material. As indicated in
In addition, in embodiments, a layer of granules can be applied over the membrane 104. For example, in embodiments, the upper surface of the cap sheet 117 can be coated with an asphalt material, and a plurality of granules applied over the cap sheet and being adhered thereto by the asphalt. The granules can be selected and applied to help increase reflectivity of sunlight. In other embodiments, granules may not be applied.
In some embodiments, the base sheet and the cap sheet can be attached or bonded together, such as by an adhesive, heat welding, or a combination thereof, or otherwise formed together as an integrated modified bitumen material sheet 115 to form the membrane 104. In still other embodiments, a single layer of a bituminous asphalt material (e.g., the base layer 116) that can be applied directly to the upper surface of the second layer 103, with the cap sheet 117 thereafter positioned over the layer of bituminous asphalt material, and attached thereto. In embodiments, the modified bitumen material sheet 115 can be applied over the upper surface of the second layer, and can be attached thereto by application of an adhesive material, which can include a hot adhesive such as a heated asphalt adhesive material, cold adhesives, or by heat welding, such as, for example, by use of a torch to apply heat to the modified bitumen material sheet 115.
For example, in embodiments, the base sheet can comprise a fibrous mat including a plurality of fibers such as glass or fiberglass fibers, carbon fibers, or other reinforcing fibers, impregnated with a polymeric material, e.g., a thermoplastic elastomer such as, styrene-butadiene-styrene. In embodiments, the cap sheet can comprise a mat formed from glass or fiberglass fibers and coated with asphalt. In some embodiments, other materials, including sheets formed from polymeric materials also can be used. In embodiments, the cap sheet further can include a face surfacing material along an upper surface thereof, e.g., in some embodiments, a plurality of granules can be applied to the upper surface of the cap sheet and adhered thereto by the asphalt coating. In embodiments, the upper surface of the base sheet can be coated with an adhesive, such as asphalt, or, in embodiments, a cold adhesive material, so as to adhere the base sheet to the cap sheet. In addition, in embodiments, a parting agent, such as silica (e.g., sand) can be applied to the upper surface of the base sheet or the lower surface of the cap sheet.
In embodiments, the modified bitumen material sheet 115 can have a thickness of 20 mils to 120 mils and in some embodiments, a thickness of 20 mils to 110 mils, 20 mils to 100 mils, 20 mils to 90 mils, 20 mils to 80 mils, 20 mils to 70 mils, 20 mils to 60 mils, 20 mils to 50 mils, 20 mils to 40 mils, 20 mils to 30 mils, 30 mils to 120 mils, 30 mils to 110 mils, 30 mils to 100 mils, 30 mils to 90 mils, 30 mils to 80 mils, 30 mils to 70 mils, 30 mils to 60 mils, 30 mils to 50 mils, 30 mils to 40 mils, 40 mils to 120 mils, 40 mils to 110 mils, 40 mils to 100 mils, 40 mils to 90 mils, 40 mils to 80 mils, 40 mils to 70 mils, 40 mils to 60 mils, 40 mils to 50 mils, 50 mils to 120 mils, 50 mils to 110 mils, 50 mils to 100 mils, 50 mils to 90 mils, 50 mils to 80 mils, 50 mils to 70 mils, 50 mils to 60 mils, 60 mils to 120 mils, 60 mils to 110 mils, 60 mils to 100 mils, 60 mils to 90 mils, 60 mils to 80 mils, 60 mils to 70 mils, 70 mils to 120 mils, 70 mils to 110 mils, 70 mils to 100 mils, 70 mils to 90 mils, 70 mils to 80 mils, 80 mils to 120 mils, 80 mils to 110 mils, 80 mils to 100 mils, 80 mils to 90 mils, 90 mils to 120 mils, 90 mils to 110 mils, 90 mils to 100 mils, 100 mils to 120 mils 100 mils to 110 mils, or 110 mils to 120 mils. Other thicknesses also could be used.
In embodiments, the second layer 103 can comprise a reinforced insulation material 120 formed according to the principles of the present disclosure; and in some embodiments, can comprise a pre-fabricated structural insulation component of the roofing system 100. In embodiments, the second layer can comprise sheets or panels that can be stacked over sheets of panels of the first layer 102, which includes the first insulation material, as shown in
In embodiments, the second layer 103 can have a thickness of 1 inch to 2.6 inches; and, in some embodiments, can have a thickness of 1 inch to 3.65 inches, 1 inch to 3.5 inches 1 inch to 3.4 inches, 1 inch to 3.3 inches, 1 inch to 3.2 inches, 1 inch to 3.1 inches, 1 inch to 3 inches, 1 inch to 2.9 inches, 1 inch to 2.8 inches. 1 inch to 2.7 inches, 1 inch to 2.6 inches, 1 inch to 2.5 inches, 1 inch to 2.4 inches, 1 inch to 2.3 inches, 1 inch to 2.2 inches, 1 inch to 2.1 inches, 1 inch to 2 inches, 1 inch to 1.9 inches, 1 inch to 1.8 inches, 1 inch to 1.7 inches, 1 inch to 1.6 inches, 1 inch to 1.5 inches, 1 inch to 1.4 inches, 1 inch to 1.3 inches, 1 inch to 1.2 inches, 1 inch to 1.1 inches.
In other embodiments, the second layer 103 can have a thickness of 1.5 inches to 3.65 inches, 1.5 inches to 3.6 inches, 1.5 inches to 3.5 inches, 1.5 inches to 3.4 inches, 1.5 inches to 3.3 inches, 1.5 inches to 3.2 inches, 1.5 inches to 3.1 inches, 1.5 inches to 3 inches, 1.5 inches to 2.9 inches, 1.5 inches to 2.8 inches, 1.5 inches to 2.7 inches, 1.5 inches to 2.6 inches, 1.5 inches to 2.5 inches, 1.5 inches to 2.4 inches, 1.5 inches to 2.3 inches, 1.5 inches to 2.2 inches, 1.5 inches to 2.1 inches, 1.5 inches to 2 inches, 1.5 inches to 1.9 inches, 1.5 inches to 1.8 inches, 1.5 inches to 1.7 inches, 1.5 inches to 1.6 inches.
In other embodiments, the second layer 103 can have a thickness of 2 inches to 3.65 inches, 2 inches to 3.6 inches, 2 inches to 3.5 inches, 2 inches to 3.4 inches, 2 inches to 3.3 inches, 2 inches to 3.2 inches, 2 inches to 3.1 inches, 2 inches to 3 inches, 2 inches to 2.9 inches, 2 inches to 2.8 inches, 2 inches to 2.7 inches, 2 inches to 2.6 inches, 2 inches to 2.5 inches, 2 inches to 2.4 inches, 2 inches to 2.3 inches, 2 inches to 2.2 inches, 2 inches to 2.1 inches. In some embodiments, the first layer can have a thickness of 2.5 inches to 3.6 inches, 2.5 inches to 3.5 inches, 2.5 inches to 3.4 inches, 2.5 inches to 3.3 inches, 2.5 inches to 3.2 inches, 2.5 inches to 3.1 inches, 2.5 inches to 3 inches, 2.5 inches to 2.9 inches, 2.5 inches to 2.8 inches, 2.5 inches to 2.7 inches, 2.5 inches to 2.6 inches. In addition, in embodiments, the first layer can have a thickness of 3 inches to 3.65 inches, 3 inches to 3.6 inches, 3 inches to 3.5 inches, 3 inches to 3.4 inches, 3 inches to 3.3 inches, 3 inches to 3.2 inches, or 3 inches to 3.1 inches. Other thicknesses also can be provided.
In embodiments, as shown in
In embodiments, the substrate 121 can have a thickness of 1 inch to 3.0 inches. In other embodiments, the substrate 121 can have a thickness of 1 inch to 2.9 inches, 1 inch to 2.8 inches. 1 inch to 2.7 inches, 1 inch to 2.6 inches, 1 inch to 2.5 inches, 1 inch to 2.4 inches, 1 inch to 2.3 inches, 1 inch to 2.2 inches, 1 inch to 2.1 inches, 1 inch to 2 inches, 1 inch to 1.9 inches, 1 inch to 1.8 inches, 1 inch to 1.7 inches, 1 inch to 1.6 inches, 1 inch to 1.5 inches, 1 inch to 1.4 inches, 1 inch to 1.3 inches, 1 inch to 1.2 inches. In other embodiments, the second layer 103 can have a thickness of 1.5 inches to 3 inches, 1.5 inches to 2.9 inches, 1.5 inches to 2.8 inches, 1.5 inches to 2.7 inches, 1.5 inches to 2.6 inches, 1.5 inches to 2.5 inches, 1.5 inches to 2.4 inches, 1.5 inches to 2.3 inches, 1.5 inches to 2.2 inches, 1.5 inches to 2.1 inches, 1.5 inches to 2 inches, 1.5 inches to 1.9 inches, 1.5 inches to 1.8 inches, 1.5 inches to 1.7 inches, 1.5 inches to 1.6 inches. In other embodiments, the second layer 103 can have a thickness of 2 inches to 3 inches, 2 inches to 2.9 inches, 2 inches to 2.8 inches, 2 inches to 2.7 inches, 2 inches to 2.6 inches, 2 inches to 2.5 inches, 2 inches to 2.4 inches, 2 inches to 2.3 inches, 2 inches to 2.2 inches, 2 inches to 2.1 inches. In some embodiments, the second layer can have a thickness of 2.5 inches to 3 inches, 2.5 inches to 2.9 inches, 2.5 inches to 2.8 inches, 2.5 inches to 2.7 inches, 2.5 inches to 2.6 inches
In embodiments, such as illustrated in
In some embodiments, the insulation material substrate 121 of the reinforced insulation material, including a polyisocyanurate, polyurethane, polystyrene, or other insulation material, can be attached to the reinforcing sublayer as part of a direct foaming process of manufacturing the insulation material. In embodiments, the reinforcing sublayer can be formed into a sheet or scrim, such as by mixing a sheet molding compound with chopped reinforcing fibers (e.g., glass, fiberglass, natural fibers, polymer fibers such as polyester, carbon fibers, or other cut or chopped fibers) and forming the mixture into a sheet, or, in some embodiments, a plurality of continuous reinforcing fibers (e.g., glass, fiberglass, natural fibers, polymer fibers such as polyester, carbon fibers, or other cut or chopped fibers) can be mixed with a resin and extruded to form the fiber reinforced polymer composite sheet.
The fiber reinforced polymer composite sheet then can be moved along a processing path, along which a foam mixture, that, in embodiments, can include a polyisocyanurate and at least one isocyanate reactive compound deposited along the first surface of the fiber reinforced polymer composite sheet. As the polyisocyanurate and at least one isocyanate reactive compound of the foam mixture reacts and expands, the reinforcing sublayer 125 can be encapsulated with or bonded to the insulation substrate so as to thus be substantially integrated with the substrate and can define the upper surface 105 of the second layer 103.
Alternatively, in some embodiments, the fiber reinforced polymer composite sheet can be formed and moved along a processing path, and a substrate comprising an insulation material, such as polyisocyanurate, polyurethane, mineral wool, expanded polystyrene foam, extended polystyrene foam, or combinations thereof, can be positioned along one side surface of the fiber reinforced polymer composite sheet, and attached thereto to form the reinforced insulation material. For example, in embodiments, an adhesive material can be applied to at least one of the fiber reinforced polymer composite sheet or the substrate, such that as the fiber reinforced polymer composite sheet and the substrate are brought into registration together, they will be adhesively attached to form the reinforced composite insulation material 120. In embodiments, the adhesive material can include isocyanate terminated urethane polymers, methacrylate's, butyl-based adhesives, polymer modified asphaltic materials, polyurethane foams, rubber contact adhesives. Other adhesive materials also can be used.
After formation, in embodiments, the reinforced insulation material can be formed into rolls, or cut into panels which can be packaged for shipment. For example, packages having one or more rolls of reinforced insulation materials, or a plurality of reinforced insulation material panels 120 stacked together can be formed. In embodiments, such packages can include 5-10 reinforced insulation material panels. In some embodiments, the packages can include 5-9 panels, 5-8 panels, 5-7 panels, 5-6 panels, 6-10 panels, 6-9 panels, 6-8 panels, 6-7 panels, 7-10 panels, 7-9 panels, 7-8 panels, 8-10 panels, 8-9 panels, or 9-10 panels. Other numbers of panels also can be provided. Still further, in other embodiments, the reinforced insulation materials can be formed as other types of roofing materials, for example, shingles, tiles, or other materials, packaged together in stacks.
In embodiments, the packages can include additional components including a membrane 104 (e.g., a roll or sheets of TPO, EPDM, PVC, or Modified Bitumen) and an adhesive material. Alternatively, in some embodiments, the reinforced insulation panels of the packages can be provided with a membrane pre-fabricated or attached thereto, with or without an additional membrane material being provided as part of the packages. Still further, in some embodiments, a plurality of insulation panels, such as for forming the first layer 102, which do not include a fiber reinforced polymer composite sheet, also can be provided as part of the packages.
In embodiments, such as shown in
In addition, in embodiments, the packages can further include one or more sensors adapted to measure temperature, impacts, penetration or leakage of water through the membrane. Other sensors or smart materials also can be provided. In embodiments, such sensors or smart materials can be applied to a surface of the reinforced insulation material; for example, placed along a surface of the reinforced insulation material (e.g., the upper surface) being inserted into the reinforced insulation material, adhered a surface of the reinforced insulation material, or combinations thereof, by installer in the field. Alternatively, in some embodiments, the packages can include reinforced insulation materials (e.g., a plurality of reinforced insulation panels) having one or more sensors integrated therewith. For example, the packages can include reinforced insulation panels with sensors attached to the second layer 103 during manufacture thereof, e.g., being laminated to the substrate, being embedded within the substrate, attached to the reinforcing sublayer, or combinations thereof, as part of the manufacturing process of the reinforced insulation panels. Still further, the packages can also include insulation panels 102 (without a reinforcing sublayer), which include one or more sensors.
In embodiments, as shown in
In embodiments, the fiber reinforced polymer composite material 137 can comprise a sheet formed by molding a plurality of reinforcing fibers 126 with a sheet molding compound. In other embodiments, the fiber reinforced polymer composite material 137 can comprise a sheet formed by a pultrusion process and including a resin and a plurality of substantially continuous reinforcing fibers. For example, in embodiments, the reinforcing fibers 126 can be mixed with a resin 127 comprising a polymer, a biodegradable material, low-carbon footprint material, or a combination thereof.
In embodiments, the fibers 126 and resin material 127 can be mixed in a selected ratio to form a skin or facer sheet of a selected thickness. By way of example only, in some embodiments, the resin and fibers can be mixed in a ratio of 10% fibers to 90% resin; and in other embodiments, can be mixed in a ratio of 10% fibers to 80% resin, 10% fibers to 70% resin, 10% fibers to 60% resin, 10% fibers to 50% resin, 10% fibers to 40% resin, 10% fibers to 30% resin, 10% fibers to 20% resin, 20% fibers to 90% resin, 20% fibers to 80% resin, 20% fibers to 70% resin, 20% fibers to 60% resin, 20% fibers to 50% resin, 20% fibers to 40% resin, 20% fibers to 30% resin, 30% fibers to 90% resin, 30% fibers to 80% resin, 30% fibers to 70% resin, 30% fibers to 60% resin, 30% fibers to 50% resin, 30% fibers to 40% resin, 40% fibers to 90% resin, 40% fibers to 80% resin, 40% fibers to 70% resin, 40% fibers to 60% resin, 40% fibers to 50% resin, 50% fibers to 90% resin, 50% fibers to 80% resin, 50% fibers to 70% resin, or 50% fibers to 60% resin. Other mixture ratios may also be used.
In some embodiments, fiber reinforced polymer composite material 137 can be formed as a sheet, and in some alternative embodiments can include a scrim having a plurality of reinforcing fibers 126 and a resin material 127 integrated therewith. The scrim material may comprise a woven material, non-woven material, mesh material, netting or belted materials, or combination thereof. The scrim material may further be comprised of polyester, glass, polyester/glass hybrid, nylon, polypropylene, or some combinations thereof. In addition, in embodiments, the scrim material of the fiber reinforced polymer composite material 137 may comprise various patterns, such as an over/under pattern, tri-directional pattern, quad-directional pattern, or some combination thereof.
In embodiments, the reinforcing fibers 126 can comprise a plurality of glass fibers, fiberglass fibers, carbon fibers, natural fibers, natural fibers (such as wood fibers and other natural fibers), or a combination thereof. For example, in embodiments, the reinforcing fibers 126 can include substantially continuous or chopped glass or carbon fibers, fiberglass filaments, or other reinforcing fibers that, when combined with appropriate resins, have a selected impact resistance.
In addition, in embodiments, the fiber reinforced polymer composite material 137 can comprise a thickness of 0.5 millimeter to 8 millimeters; and in some embodiments, a thickness of 0.5 millimeter to 7 millimeters, 0.5 millimeter to 6 millimeters, 0.5 millimeter to 5 millimeters, 0.5 millimeter to 4 millimeters, 0.5 millimeter to 3 millimeters, 0.5 millimeter to 2 millimeters, 0.5 millimeter to 1 millimeter, 1 millimeter to 8 millimeters, 1 millimeter to 7 millimeters, 1 millimeter to 6 millimeters, 1 millimeter to 5 millimeters, 1 millimeter to 4 millimeters, 1 millimeter to 3 millimeters, 1 millimeter to 2 millimeters, 2 millimeters to 8 millimeters, 2 millimeters to 7 millimeters, 2 millimeters to 6 millimeters, 2 millimeters to 5 millimeters, 2 millimeters to 4 millimeters, 2 millimeters to 3 millimeters, 3 millimeters to 8 millimeters, 3 millimeters to 7 millimeters, 3 millimeters to 6 millimeters, 3 millimeters to 5 millimeters, 3 millimeters to 4 millimeters, 4 millimeters to 8 millimeters, 4 millimeters to 7 millimeters, 4 millimeters to 6 millimeters, 4 millimeters to 5 millimeters, 5 millimeters to 8 millimeters, 5 millimeters to 7 millimeters, 5 millimeters to 6 millimeters, 6 millimeters to 8 millimeters, 6 millimeters to 7 millimeters, or 7 millimeters to 8 millimeters. Other thicknesses of the fiber reinforced polymer composite material also can be used.
Further, in some embodiments, an additional reinforcing sublayer 128 (
In one example embodiment, shown in
In embodiments, such as shown in
In addition, in embodiments, the second reinforcing layer 128 can comprise a reinforced polymer composite material skin 136 that is applied along the second surface of the substrate opposite the first reinforcing sublayer, as shown in
In embodiments, one or both of the first and second reinforcing sublayers 125 and 128 can be formed with the substrate 121. For example, in embodiments, one or both of the first and second reinforcing layers can be formed with the substrate as part of a direct foaming process wherein, during formation of the substrate, the polyisocyanurate insulation material of the substrate is directly formed onto the first and/or second reinforcing sublayers, so as to form the integrated reinforced insulation material 120.
In one example embodiment shown in
In an example embodiment shown in
As further illustrated in
In embodiments, the fiber reinforced polymer composite material skins 137 and 136 of the first and second reinforcing sublayers 125 and 128 shown in the embodiments of
In addition, in some embodiments, such as indicated in
For example, as indicated in
In addition, in some embodiments, one or more smart materials and sensors also can be integrated into the second layer. For example, sensors adapted to measure temperature, impacts, penetration or leakage of water through the membrane, and other sensors can be provided. Such sensors or smart materials can be integrated with the second layer 103 during manufacture thereof, e.g., being embedded into or laminated to the substrate with the reinforcing sublayer, or, in some embodiments, can be applied along a surface, of the reinforcing sublayer (e.g., the upper surface thereof) prior to installation of the membrane in the field. In embodiments, sensors also can be provided as part of a package of roofing materials, which, in some embodiments, could include one or more rolls or panels or roofing materials, e.g., including a plurality of reinforced insulation sheets, panels, shingles, tiles, etc., with sensors integrated therewith.
In
Thereafter, a second layer 103 comprising a second insulation material, e.g., the reinforced insulation material 120, is applied over the first layer 102. In embodiments, a layer of an adhesive material will be applied to an upper surface 129 of the first layer 102 for attaching the first layer 102 to the second layer 103. In embodiments, such as shown in
As shown in
Alternatively, in embodiments where the reinforced insulation panels each include a TPO, EPDM, PVC, or modified Bitumen membrane pre-attached to the upper surfaces thereof. For example, in embodiments, as illustrated in
Each of the roofing systems shown in
In addition,
The conventional roofing system example (shown on the left) included a 0.5″ thick plywood deck, a 1.5″ 20 psi foam insulation material applied over the plywood deck, a 0.5″ gypsum coverboard adhered to the upper surface of the 1.5″ 20 psi foam insulation, and a modified bitumen material (including an asphaltic base sheet and an asphaltic cap sheet attached to the base sheet with an adhesive) attached to the upper surface of the coverboard with a cold applied membrane adhesive. A plurality of granules further was adhesively attached to the upper surface of the cap sheet of the two-ply modified bitumen material. The roofing system formed according to the principles of the present disclosure (shown on the right) did not include a coverboard, and comprised a 0.5″ plywood deck, a 1.5″ 20 psi foam insulation applied over the plywood deck, a reinforced insulation material including a 2 mm GRP+2″ 20 psi foam insulation material, formed in accordance with embodiments of the present disclosure, applied to the upper surface of the 1.5″ 20 psi foam insulation material, and a modified bitumen material (including an asphaltic base sheet and an asphaltic cap sheet attached to the base sheet with an adhesive) attached to the upper surface of the reinforced insulation panel with a cold applied membrane adhesive material. In addition, a plurality of granules was adhesively attached to the upper surface of cap sheet of the modified bitumen material.
Both roofing systems were subjected to testing in accordance with the FM 4473testing standard for Very Severe Hail Resistance, during which the roofing systems were impacted by 2″ ice balls propelled at 152-160 feet per second, the ice balls striking the roofing systems with an impact force or energy of approximately 80J (58 ft-lb). As can be seen in
The foregoing description generally illustrates and describes various embodiments of the present disclosure. It will, however, be understood by those skilled in the art that various changes and modifications can be made to the above-discussed construction of the present disclosure without departing from the spirit and scope of the present disclosure as disclosed herein, and that it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as being illustrative, and not to be taken in a limiting sense. Furthermore, the scope of the present disclosure shall be construed to cover various modifications, combinations, additions, alterations, etc., above and to the above-described embodiments, which shall be considered to be within the scope of the present disclosure. Accordingly, various features and characteristics of the present disclosure as discussed herein may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the present disclosure, and numerous variations, modifications, and additions further can be made thereto without departing from the spirit and scope of the present disclosure.
The present application claims the benefit of U.S. Provisional Application No. 63/468,299, filed May 23, 2023.
| Number | Date | Country | |
|---|---|---|---|
| 63468299 | May 2023 | US |
