ROOFING SYSTEMS AND ROOFING BOARDS WITH NON-HALOGENATED FIRE RETARDANT

• US 20150354220A1
• Filed: 06/09/2014
• Published: 12/10/2015
• Est. Priority Date: 06/09/2014
• Status: Active Grant

• Current Assignee: Johns Manville Corporation (Berkshire Hathaway Incorporated)
• Original Assignee: Johns Manville Corporation (Berkshire Hathaway Incorporated)
• Inventors: Nandi, Malay, Wang, Lance, Asrar, Jawed
• Granted Patent: US 9,528,269 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B32B 11/046 of synthetic resin
• CPC Class Codes: B32B 2262/101 Glass fibres
• 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 2307/558 Impact strength, toughness
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof
• CPC Class Codes: B32B 2419/06 Roofs, roof membranes
• 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 27/18 characterised by the use of special additives
• CPC Class Codes: B32B 27/30 comprising vinyl (co)polymers; comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 5/245 another layer next to it being a foam layer
• CPC Class Codes: C08G 18/14 Manufacture of cellular products
• CPC Class Codes: C08G 18/288 Compounds containing at least one heteroatom other than oxygen or nitrogen
• CPC Class Codes: C08G 18/42 Polycondensates having carboxylic or carbonic ester groups in the main chain
• CPC Class Codes: C08G 18/72 Polyisocyanates or polyisothiocyanates
• CPC Class Codes: C08G 18/791 containing isocyanurate groups
• CPC Class Codes: C08G 2101/00 Manufacture of cellular products
• CPC Class Codes: C08G 2115/02 : to isocyanurate groups
• CPC Class Codes: C08G 2330/00 : Thermal insulation material
• CPC Class Codes: C08J 2203/14 : Saturated hydrocarbons, e.g. butane; Unspecified hydrocarbons
• CPC Class Codes: C08J 2207/00 : Foams characterised by their intended use
• CPC Class Codes: C08J 2375/06 : from polyesters
• CPC Class Codes: C08J 2375/08 : from polyethers
• CPC Class Codes: C08J 2483/12 : containing polyether sequences
• CPC Class Codes: C08J 9/0023 : containing oxygen
• CPC Class Codes: C08J 9/0038 : containing phosphorus
• CPC Class Codes: C08J 9/0061 : characterized by the use of several polymeric components
• CPC Class Codes: C08J 9/0095 : Mixtures of at least two compounding ingredients belonging to different one-dot groups
• CPC Class Codes: C08J 9/141 : Hydrocarbons
• CPC Class Codes: E04B 1/942 : slab-shaped
• CPC Class Codes: E04B 2103/04 : of plastics, fibrous material or wood
• CPC Class Codes: E04C 2/205 : of foamed plastics, or of plastics and foamed plastics, optionally reinforced
• CPC Class Codes: E04C 2/44 : characterised by the purpose
• 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 12/002 : Sheets of flexible material, e.g. roofing tile underlay
• CPC Class Codes: E04D 13/16 : Insulating devices or arrangements in so far as the roof covering is concerned, e.g. characterised by the material or composition of the roof insulating material or its integration in the roof structure
• CPC Class Codes: E04D 13/1643 : the roof structure being formed by load bearing corrugated sheets, e.g. profiled sheet metal roofs
• CPC Class Codes: E04D 5/06 : by making use of plastics
• CPC Class Codes: Y10T 428/249953 : Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249987 : With nonvoid component of specified composition
• CPC Class Codes: Y10T 428/24999 : Inorganic
• CPC Class Codes: Y10T 428/249993 : Hydrocarbon polymer

Abstract

According to one embodiment, a halogen free roof system is described. The roof system includes a structural deck that is positioned above joists or other support members. Polyisocyanurate foam insulation is positioned atop the structural deck. The polyisocyanurate foam insulation has an isocyanate index greater than 200 and includes a polyisocyanurate core having a halogen free fire retardant. A water proof membrane is positioned atop the polyisocyanurate foam insulation. The polyisocyanurate core is able to form a sufficiently stable char when exposed to flame conditions such that the polyisocyanurate core is able to pass the ASTM E-84 test.

Claims

1. A roof system comprising:

a structural deck positioned atop joists or other support members of the roof system;

a plurality of polyisocyanurate foam insulation boards positioned atop the structural deck to form an insulation layer for the roof system, each polyisocyanurate foam insulation board having an isocyanate index greater than 200; and

a water proof membrane positioned atop the plurality of polyisocyanurate foam insulation boards to form a water proof layer for the roof system;

wherein each polyisocyanurate foam insulation board includes a polyisocyanurate core produced from;

an isocyanate;

a polyol; and

at least one isocyanate reactive mono-hydroxyl phosphorus containing non-halogenated fire retardant, the polyisocyanurate core forming a sufficiently stable char when exposed to flame conditions in accordance with an ASTM E-84 that enables the polyisocyanurate core to pass the ASTM E-84 test, wherein the polyisocyanurate core foam board comprises an initial R-value of at least 6.4, and wherein the polyisocyanurate core foam board exhibits an ASTM E1354-11b performance equivalent with or better than a polyisocyanurate foam insulation board having a halogenated fire retardant tris(2-chloroisopropyl)phosphate (TCPP).

2. The roof system of claim 1, further comprising a plurality of cover boards positioned between the plurality of polyisocyanurate foam insulation boards and the water proof membrane to form a protective layer for the roof system

3. The roof system of claim 2, wherein each cover board includes a polyisocyanurate core produced from:

an isocyanate;

a polyol; and

at least one phosphorus containing non-halogenated fire retardant.

4. The roof system of claim 1, wherein the polyisocyanurate core further comprises between 5 and 10 weight percent of a hydrocarbon blowing agent.

5. The roof system of claim 1, wherein each foam insulation board further includes a glass fiber mat facer attached to at least one surface thereof.

6. The roof system of claim 1, wherein the water proof membrane includes:

built-up roof;

modified bitumen;

thermoplastic olefin (TPO);

polyvinyl chloride (PVC);

ethylene propylene diene monomer (EPDM);

or

metal.

7. The roof system of claim 1, wherein the at least one isocyanate reactive mono-hydroxyl phosphorus containing non-halogenated fire retardant includes one or more of:

organo-phosphate;

organo-phosphite;

or

organo-phosphonate.

8. The roof system of claim 7, wherein the isocyanate reactive mono-hydroxyl phosphorous containing non-halogenated fire retardant is diethyl hydroxymethyl phosphonate (DEHMP).

10. The roof system of claim 1, wherein the polyisocyanurate core comprises an average foam cell size of no more than 200 microns.

11. The roof system of claim 1, wherein each foam insulation board has a density of between about 1.5 and 2.5 pcf.

9. (canceled)

12. A method of forming a roof system comprising:

positioning a structural deck atop joists or other support members of the roof system;

positioning a plurality of polyisocyanurate foam insulation boards atop the structural deck to form an insulation layer for the roof system; and

positioning a water proof membrane atop the plurality of polyisocyanurate foam insulation boards to form a water proof layer for the roof system;

wherein each polyisocyanurate foam insulation board includes a polyisocyanurate core produced from;

an isocyanate;

a polyol; and

at least one isocyanate reactive mono-functional phosphorus containing non-halogenated fire retardant, the polyisocyanurate core forming a sufficiently stable char when exposed to flame conditions in accordance with an ASTM E-84 that enables the polyisocyanurate core to pass the ASTM E-84 test, wherein the polyisocyanurate foam insulation boards comprise an initial R-value of at least 6.4, and wherein the polyisocyanurate foam insulation boards exhibit an ASTM E1354-11b performance equivalent with or better than a polyisocyanurate foam insulation board having a halogenated fire retardant tris(2-chloroisopropyl)phosphate (TCPP).

13. The method of claim 12, further comprising positioning a plurality of cover boards atop the plurality of polyisocyanurate foam insulation boards to form a protective layer for the roof system.

14. The method of claim 13, wherein each cover board includes a polyisocyanurate core produced from:

an isocyanate;

a polyol; and

at least one phosphorus containing non-halogenated fire retardant.

15. The method of claim 12, wherein the polyisocyanurate core further comprises between 5 and 10 weight percent of a hydrocarbon blowing agent.

16. The method of claim 12, further comprising attaching a glass fiber mat facer to at least surface of the polyisocyanurate core.

17. The method of claim 12, wherein the water proof membrane includes:

built-up roof;

modified bitumen;

thermoplastic olefin (TPO);

polyvinyl chloride (PVC);

ethylene propylene diene monomer (EPDM);

or

metal.

18. The method of claim 12, wherein the isocyanate reactive mono-functional phosphorous containing non-halogenated fire retardant includes one or more of:

organo-phosphate;

organo-phosphite;

or

organo-phosphonate.

19. The method of claim 12, wherein the isocyanate reactive mono-functional phosphorous containing non-halogenated fire retardant is diethyl hydroxymethyl phosphonate (DEHMP).

21. The method of claim 12, wherein each foam insulation board has a density of between about 1.5 and 2.5 pcf.

20. (canceled)

22. A halogen free roof system comprising:

polyisocyanurate foam insulation configured to be positioned atop a structural deck that is supported by joists or other structural support members, the polyisocyanurate foam insulation having an isocyanate index greater than 200, the polyisocyanurate foam insulation including a polyisocyanurate core having a halogen free fire retardant, the halogen free fire retardant comprising an isocyanate reactive mono-functional phosphorus containing fire retardant, the polyisocyanurate core forming a sufficiently stable char when exposed to flame conditions in accordance with an ASTM E-84 such that the polyisocyanurate core passes the ASTM E-84 test; and

a water proof membrane positioned atop the polyisocyanurate foam insulation.

23. The halogen free roof system of claim 22, further comprising a coverboard positioned atop the polyisocyanurate foam insulation, the coverboard including a halogen free fire retardant.

24. The halogen free roof system of claim 23, wherein the coverboard comprises a polyisocyanurate foam core.

25. The halogen free roof system of claim 22, wherein the water proof membrane includes:

built-up roof;

modified bitumen;

thermoplastic olefin (TPO);

ethylene propylene diene monomer (EPDM);

or

metal.

26. The halogen free roof system of claim 22, wherein the polyisocyanurate foam insulation includes between 5 and 10 weight percent of a hydrocarbon blowing agent.

28. The halogen free roof system of claim 22, wherein the halogen free fire retardant is diethyl hydroxymethyl phosphonate (DEHMP).

29. The halogen free roof system of claim 22, wherein the polyisocyanurate core comprises an average foam cell size of about 125 microns.

27. (canceled)