Fire-rated roofing system

• US 10,357,946 B2
• Filed: 08/03/2016
• Issued: 07/23/2019
• Est. Priority Date: 01/21/2016
• Status: Active Grant

• Current Assignee: Carlisle Intangible Company (Carlisle Cos., Inc.)
• Original Assignee: Carlisle Intangible Company (Carlisle Cos., Inc.)
• Inventors: Leatherman, Matthew John, Gish, Brian
• Primary Examiner(s): Figueroa, Adriana
• Assistant Examiner(s): Fonseca, Jessie T
• Application Number:
  US15/227,274
• Publication Number:
  US 20170210100A1
• Time in Patent Office: 1,084 Days
• CPC Class Codes: B32B 11/10 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 15/04 comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a bituminous or tarry layer B32B11/08; next to a water-setting substance layer B32B13/06; next to a glass layer B32B17/061; next to a cellulosic plastic layer B32B23/042
• CPC Class Codes: B32B 15/06 of natural rubber or synthetic rubber
• CPC Class Codes: B32B 15/082 comprising vinyl resins; comprising acrylic resins
• CPC Class Codes: B32B 15/085 comprising polyolefins
• CPC Class Codes: B32B 15/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 15/18 comprising iron or steel B32B15/011, B32B15/012 and B32B15/013 take precedence
• CPC Class Codes: B32B 15/20 comprising aluminium or copper B32B15/016 and B32B15/017 take precedence
• CPC Class Codes: B32B 19/06 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 19/08 comprising asbestos
• CPC Class Codes: B32B 2250/04 4 layers
• CPC Class Codes: B32B 2250/05 5 or more layers
• CPC Class Codes: B32B 2262/0269 Aromatic polyamide fibres
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/10 Inorganic fibres layered products comprising a layer of natural mineral fibres B32B19/00
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2262/108 Rockwool fibres
• CPC Class Codes: B32B 2262/14 Mixture of at least two fibres made of different materials
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/3065 : Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/50 : having particular mechanical properties
• CPC Class Codes: B32B 2307/546 : Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/718 : Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2307/7265 : Non-permeable
• CPC Class Codes: B32B 2307/732 : Dimensional properties
• CPC Class Codes: B32B 2419/06 : Roofs, roof membranes
• CPC Class Codes: B32B 25/14 : comprising synthetic rubber copolymers B32B25/18 and B32B25/20 take precedence
• CPC Class Codes: B32B 25/16 : comprising polydienes homopolymers or poly-halodienes homopolymers B32B25/12 takes precedence
• CPC Class Codes: B32B 27/06 : as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 27/08 : of synthetic resin
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/304 : comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/308 : comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/06 : characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
• CPC Class Codes: B32B 5/24 : one layer being a fibrous or filamentary layer
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 7/04 : Interconnection of layers
• CPC Class Codes: E04B 1/941 : Building elements specially adapted therefor
• CPC Class Codes: E04D 1/28 : Roofing elements comprising two or more layers, e.g. for insulation
• CPC Class Codes: E04D 11/02 : Build-up roofs, i.e. consisting of two or more layers bonded together in situ, at least one of the layers being of watertight composition gravelling of flat roofs E04D7/00; venting or ventilation E04D13/17
• CPC Class Codes: E04D 5/04 : by making use of metal foils
• CPC Class Codes: E04D 5/10 : by making use of compounded or laminated materials, e.g. metal foils or plastic films coated with bitumen

Abstract

A fire-resistant polymeric membrane includes a polymer layer such as PVC, TPO, or EPDM affixed to a carbon fiber composite. The carbon fiber composite includes one or two layers of non-woven carbon fibers and at least one of an inert fiber mat or a metal foil layer, wherein the metal foil layer has a melting temperature of at least about 660° C. The present invention also provides an underlayment, wherein the underlayment is formed from one or more fibrous carbon layers affixed to at least one of an inert fiber mat or a metal foil having a melting temperature greater than 660° C.

Claims

1. A fire-resistant composite comprising:

a first layer comprising a flexible polyolefin sheet having a thickness of 45-80 mils, the first layer comprising a reinforcing material;

a second layer comprising first and second carbon fiber sheets with a metal foil positioned between said first and second carbon fiber sheets, the metal foil having a melting temperature above 660°

C.; and

wherein said composite passes ASTM E 108 and is configured to be installed on a roof exterior.

2. The fire-resistant composite claimed in claim 1 wherein said first layer is affixed to said second layer to form a composite sheet.

3. The fire-resistant composite claimed in claim 1 wherein at least one of said carbon fiber sheets is tufted.

4. The fire-resistant composite claimed in claim 3 wherein said first and second carbon fiber sheets are affixed to said metal foil and to each other by tufting.

5. The fire-resistant composite claimed in claim 1 wherein said flexible polyolefin sheet is selected from the group consisting of thermoplastic polyolefin (TPO), ethylene propylene monomer rubber (EPM), ethylene propylene diene monomer rubber (EPDM).

6. The fire-resistant composite claimed in claim 1 wherein said metal foil is selected from the group consisting of aluminum, stainless steel, iron, iron alloys, titanium, nickel, chromium, tungsten, and copper.

7. The fire-resistant composite claimed in claim 6 wherein said metal foil has a melting temperature of at least about 1100°

C.

8. The fire-resistant composite claimed in claim 7 wherein said metal foil has a melting temperature of at least 1200°

C.

9. The fire-resistant composite claimed in claim 1 wherein the first carbon fiber sheet and the second carbon fiber sheet have a combined basis weight of at least 3 ounces per square yard.

10. The fire-resistant composite claimed in claim 1 wherein the first carbon fiber sheet and the second carbon fiber sheet have a combined basis weight of at least 6 ounces per square yard.

11. The fire-resistant composite claimed in claim 1 wherein the first carbon fiber sheet and the second carbon fiber sheet have a combined basis weight of at least 9 ounces per square yard.

12. The fire-resistant composite claimed in claim 1 wherein the first carbon fiber sheet and the second carbon fiber sheet have a combined basis weight of 9-12 ounces per square yard.

13. The fire-resistant composite claimed in claim 1 wherein said flexible polyolefin sheet comprises a first ply and a second ply and wherein said first ply includes the reinforcing material.