Fire-rated roofing system

• US 10,696,024 B2
• Filed: 06/26/2019
• Issued: 06/30/2020
• 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): Fonseca, Jessie T
• Application Number:
  US16/453,608
• Publication Number:
  US 20190315100A1
• Time in Patent Office: 370 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
• 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 polymeric sheet; and

a second layer, the second layer comprising a first carbon fiber sheet and a second carbon fiber sheet with an inert fiber mat positioned between the first carbon fiber sheet and the second carbon fiber sheet, the second layer further comprising the inert fiber mat positioned between a metal foil and one of the first carbon fiber sheet or the second carbon fiber sheet, and wherein the second layer further comprises a third carbon fiber sheet positioned between the metal foil and the inert fiber mat.

2. The fire-resistant composite claimed in claim 1 wherein the inert fiber mat is selected from the group consisting of a glass scrim, woven glass fibers, asbestos, elastinite, and basalt.

3. The fire-resistant composite of claim 1, wherein the flexible polymeric sheet is selected from the group consisting of polyvinyl chloride (PVC), thermoplastic polyolefin (TPO), ethylene propylene monomer rubber (EPM), ethylene propylene diene monomer rubber (EPDM), chlorosulfonated polyethylene, and flexible acrylics.

4. The fire-resistant composite of claim 1, wherein the first layer comprises an upper ply and a lower ply, the first layer further comprises a reinforcing material wherein the reinforcing material is located between the upper ply and the lower ply.

5. A fire-resistant roofing underlayment comprising:

at least three carbon fiber layers, the three carbon fiber layers including a first carbon fiber layer, a second carbon fiber layer, and a third carbon fiber layer; and

an inert fiber mat positioned between the first carbon fiber layer and the second carbon fiber layer, the inert mat positioned between a metal foil and one of the first carbon fiber layer or the second carbon fiber layer, and the third carbon fiber layer positioned between the metal foil and the inert fiber mat, the metal foil layer having a melting temperature greater than about 660°

C.

6. The fire-resistant roofing underlayment of claim 5, wherein the first carbon fiber layer has a basis weight of at least 3 ounces per square yard.

7. The fire-resistant roofing underlayment of claim 5, wherein the second carbon fiber layer has a basis weight of at least 3 ounces per square yard.

8. The fire-resistant roofing underlayment of claim 5, wherein the third carbon fiber layer has a basis weight of at least 3 ounces per square yard.

9. The fire-resistant roofing underlayment of claim 5, wherein the first carbon fiber layer and the second carbon fiber layer each have a basis weight of at least 3 ounces per square yard.

10. The fire-resistant roofing underlayment of claim 5, wherein the first carbon fiber layer and the third carbon fiber layer each have a basis weight of at least 3 ounces per square yard.

11. The fire-resistant roofing underlayment of claim 5, wherein the second carbon fiber layer and the third carbon fiber layer each have a basis weight of at least 3 ounces per square yard.

12. The fire-resistant roofing underlayment of claim 5, wherein the first carbon fiber layer, the second carbon fiber layer, and the third carbon fiber layer each have a basis weight of at least 3 ounces per square yard.

17. The fire-resistant roofing underlayment of claim 5, wherein the fire-resistant roofing underlayment passes ASTM E 108 and is configured to be installed on a roof exterior.

13. A roof structure comprising:

a roof deck covered with a fire-resistant composite membrane comprising;

a first layer comprising a flexible polymeric sheet; and

a second layer affixed to the first layer, the second layer comprising at least one carbon fiber sheet and at least one of an inert fiber mat or a metal foil, the metal foil having a melting temperature above about 660°

C., wherein the second layer comprises at least two carbon fiber sheets separated by at least one of the inert fiber mat or the metal foil, and the at least one of the inert fiber mat or the metal foil is between the at least two carbon fiber sheets, wherein the at least two carbon fiber sheets have a combined basis weight of at least 3 ounces per square yard.

14. The roof structure of claim 13, wherein the flexible polymeric sheet is selected from the group consisting of polyvinyl chloride (PVC), thermoplastic polyolefin (TPO), ethylene propylene monomer rubber (EPM), ethylene propylene diene monomer rubber (EPDM), chlorosulfonated polyethylene, and flexible acrylics.

15. The roof structure of claim 13, wherein the first layer comprises an upper ply and a lower ply, the first layer further comprises a reinforcing material wherein the reinforcing material is located between the upper ply and the lower ply.

16. The roof structure of claim 13, the fire-resistant composite membrane passes ASTM E 108 and is configured to be installed on a roof exterior.