Coated roofing insulation and roofing systems including such insulations

• US 6,398,976 B1
• Filed: 09/20/2000
• Issued: 06/04/2002
• Est. Priority Date: 02/18/1999
• Status: Expired due to Term

• Current Assignee: Johns Manville International, Inc. (Berkshire Hathaway Incorporated)
• Original Assignee: Johns Manville International, Inc. (Berkshire Hathaway Incorporated)
• Inventors: DePorter, Craig Donald, Sandoval, Christopher Paul, Bauer, Mary Margaret Georgene, Battaglioli, Mauro Vittorio
• Primary Examiner(s): MARCHESCHI, MICHAEL A
• Application Number:
  US09/665,738
• Time in Patent Office: 622 Days
• Field of Search: 252/62, 106/217.01, 106/164.5, 106/162.51, 106/164.53, 106/164.6, 106/204.01, 106/216.1, 106/DIG.2, 106/282, 106/632, 106/634, 428/141, 428/146, 428/147, 428/148, 427/372.2, 427/397.8, 427/186
• US Class Current: 252/62
• CPC Class Codes: C04B 14/022 Carbon
• CPC Class Codes: C04B 14/104 Bentonite, e.g. montmorillonite
• CPC Class Codes: C04B 14/106 Kaolin
• CPC Class Codes: C04B 14/185 expanded
• CPC Class Codes: C04B 14/20 Mica; Vermiculite mechanical splitting B28D
• CPC Class Codes: C04B 14/303 Alumina
• CPC Class Codes: C04B 18/24 Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper , cork
• CPC Class Codes: C04B 18/241 Paper, e.g. waste paper; Paper pulp
• CPC Class Codes: C04B 2111/00586 Roofing materials
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 22/148 Aluminium-sulfate
• CPC Class Codes: C04B 24/2623 Polyvinylalcohols; Polyvinylacetates
• CPC Class Codes: C04B 24/2641 Polyacrylates; Polymethacrylates
• CPC Class Codes: C04B 24/36 Bituminous materials, e.g. tar, pitch C04B24/243 takes precedence
• CPC Class Codes: C04B 26/02 Macromolecular compounds
• CPC Class Codes: C04B 26/04 obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: C04B 26/26 Bituminous materials, e.g. tar, pitch C08L95/00 takes precedence
• CPC Class Codes: C04B 28/26 Silicates of the alkali metals
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/478 Bitumen, asphalt, e.g. paraffin
• CPC Class Codes: C04B 41/4857 : Other macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: C04B 41/5037 : Clay, Kaolin
• CPC Class Codes: C04B 41/5089 : Silica sols, alkyl, ammonium or alkali metal silicate cements
• CPC Class Codes: C04B 41/63 : Macromolecular compounds
• CPC Class Codes: C04B 41/68 : Silicic acid; Silicates
• CPC Class Codes: D21J 1/165 : Roofing material
• CPC Class Codes: D21J 1/20 : Insulating board
• CPC Class Codes: E04B 2001/746 : Recycled materials, e.g. made of used tires, bumpers or newspapers
• 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: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10S 106/02 : Perlite
• CPC Class Codes: Y10T 428/24355 : Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
• CPC Class Codes: Y10T 428/24397 : Carbohydrate
• CPC Class Codes: Y10T 428/24405 : Polymer or resin [e.g., natural or synthetic rubber, etc.]
• CPC Class Codes: Y10T 428/24413 : Metal or metal compound
• CPC Class Codes: Y10T 428/2991 : Coated
• CPC Class Codes: Y10T 428/2998 : including synthetic resin or polymer

Abstract

A single ply membrane roofing system includes a roofing insulation board which, preferably, is at least 45% by dry weight expanded perlite. One major surface of the insulation board is coated with a latex coating comprising, by dry weight, between 48.3% and 96% clay; between 3.1% and 33.3% latex; and between 0% and 34% sodium silicate. A single ply roofing membrane is adhered to the coated major surface of the insulation board with a roofing contact adhesive.

Claims

1. A method of making a coated roofing insulation board, comprising:

mixing together the following ingredients in water to form a slurry;

expanded perlite about 45% to about 76% by dry weight;

cellulosic fibers about 15% to about 45% by dry weight;

latex binder about 0.1% to about 10% by dry weight;

bituminous material about 2% to about 9% by dry weight; and

alum about 0% to about 3% by dry weight;

forming the slurry into a wet mat;

applying a coating comprising, by dry weight about 48.3% to about 96% filler;

about 3.1% to about 33.3% latex; and

0% to about 34% sodium silicate, to a first major surface of the wet mat; and

drying the mat and coating to form a coated insulation board.

2. The method according to claim 1, wherein:

the dry latex coating weighs between 1.1 grams and 12.0 grams per square foot.

3. The method according to claim 1, wherein in the coating;

the filler is kaolin cl ay and the latex is selected from a group consisting of acrylic latexes;

poly(vinyl acetate) latexes and styrene/butadiene rubber latexes.

4. A method of making a coated roofing insulation board comprising:

mixing together the following ingredients in water to form slurry;

expanded perlite between about 45% and about 76% by dry weight;

cellulosic fibers between about 15% and about 45% by dry weight;

starch binder about 0.1% to about 10% by dry weight;

bituminous material about 2% to about 9% by dry weight; and

alum about 0% to about 3% by dry weight;

forming the slurry into a wet mat;

applying a coating comprising, by dry weight, about 48.3% to about 96% filler;

about 3.1% to about 33.3% latex; and

0% to about 34% sodium silicate, to a first major surface of the wet mat; and

drying the mat and coating to form a coated insulation board.

5. The method according to claim 4, wherein:

the dry latex coating weighs between 1.1 grams and 12.0 grams per square foot.

6. The method according to claim 4, wherein:

the filler is kaolin clay and the latex is selected from a group consisting of acrylic latexes;

poly(vinyl acetate) latexes and styrene/butadiene rubber latexes.