Fire retardant EPDM roofing membrane compositons for use on high-sloped roofs

• US 6,632,509 B1
• Filed: 05/06/1998
• Issued: 10/14/2003
• Est. Priority Date: 05/06/1998
• Status: Active Grant

• Current Assignee: Firestone Building Products Company LLC (Bridgestone Corporation)
• Original Assignee: BFS Diversified Products LLC (Bridgestone Corporation)
• Inventors: Brandt, Gregory A., Davis, James A., Barham, William F. Jr.
• Primary Examiner(s): SZEKELY, PETER A
• Application Number:
  US09/073,686
• Time in Patent Office: 1,987 Days
• Field of Search: 428/144, 428/147, 427/387, 427/393.5, 427/385.5, 524/412, 524/445, 524/449, 524/451, 524/464
• US Class Current: 428/147
• CPC Class Codes: C08L 23/16 Elastomeric ethene-propene or ethene-propene-diene copolymers, e.g. EPR and EPDM rubbers
• CPC Class Codes: C08L 2666/04 Macromolecular compounds according to groups C08L7/00 - C08L49/00, or C08L55/00 - C08L57/00; Derivatives thereof
• CPC Class Codes: E04D 5/06 by making use of plastics
• CPC Class Codes: Y10T 428/24405 Polymer or resin [e.g., natural or synthetic rubber, etc.]

Abstract

Fire retardant sheeting materials for roofing having improved burn resistivity and are suitable for use on roofs having inclines of at least 1 inch per linear foot. These sheeting materials are prepared from a polymeric composition of matter comprising a base polymer containing at least one ethylene-propylene-diene terpolymer, the base polymer having up to about 2 percent by weight crystallinity; from about 85 to about 175 parts by weight of at least one non-combustible mineral filler per 100 parts of the base polymer; from about 30 to about 50 parts by weight of a processing material, per 100 parts of the base polymer; from about 50 to about 80 parts by weight of at least one fire retardant additive, per 100 parts of the base polymer; and from about 1.5 to about 10 parts by weight of a sulfur cure package per 100 parts of the base polymer. The composition contains at least 40 percent non-combustible materials, and the sheeting material has a limiting oxygen index (LOI) of at least 40 percent when tested in accordance with ASTM D2863-91. A method of covering a roof comprises the steps of applying layers of the fire retardant roof sheeting material prepared from the polymeric composition of matter, to the roof being covered, overlapping adjacent edges of the roof sheet material, and adhesively seaming the overlapped layers of the roof sheet material together to form a continuous roofing membrane.

Claims

1. A fire retardant roof sheeting membrane for sloped roofs having an incline of at least 1 inch per linear foot, formed from a composition comprising:

a base polymer containing at least one ethylene-propylene-diene terpolymer, said base polymer having up to about 2 percent by weight crystallinity;

from about 85 to about 175 parts by weight of at least one non-combustible mineral filler per 100 parts of said base polymer;

from about 30 to about 50 parts by weight of a processing material, per 100 parts of said base polymer;

from about 50 to about 80 parts by weight of at least one fire retardant additive, per 100 parts of said base polymer, wherein said fire retardant additive includes at least a bromine-containing additive and antimony trioxide (Sb₂O₃); and

from about 1.5 to about 10 parts by weight of a cure package per 100 parts of said base polymer, the sheeting membrane composition containing at least 40 percent non-combustible materials, being calenderable for use on a roof, having a limiting oxygen index (LOI) of at least 40 percent oxygen when tested in accordance with ASTM D2863-91, and capable of passing the UL-790 Test for Fire Resistance of Roof Covering Materials for sloped roofs having an incline of at least 1 inch per linear foot.

2. The fire retardant roof sheeting membrane as set forth in claim 1, further comprising about 30 to 90 parts by weight of at least one black filler, per 100 parts of said base polymer.

3. The fire retardant roof sheeting membrane as set forth in claim 1, wherein said base polymer further contains a second ethylene-propylene-diene terpolymer.

4. The fire retardant roof sheeting membrane as set forth in claim 1, wherein said base polymer further contains a polymer forming a mixture with said at least one terpolymer wherein said polymer forming said mixture is selected from the group consisting of copolymers prepared from monomers containing at least 2 carbon atoms, blended in relative proportions with said terpolymer so that the overall crystallinity of said base polymer is up to about 2 percent by weight.

5. The fire retardant roof sheeting membrane as set forth in claim 1, wherein said non-combustible mineral filler is selected from the group consisting of hard clays, soft clays, chemically modified clays, mica, talc, alumina trihydrate, calcium carbonate, titanium dioxide, amorphous precipitated hydrated silica and mixtures thereof.

6. The fire retardant roof sheeting membrane as set forth in claim 5, wherein said non-combustible mineral filler includes soft clays and talc.

7. The fire retardant roof sheeting membrane as set forth in claim 1, wherein said processing material is selected from the group consisting of paraffinic oils, naphthenic oils and waxes and mixtures thereof.

8. The fire retardant roof sheeting membrane as set forth in claim 1, wherein said bromine-containing additive is decabromodiphenyl oxide (DBDPO).

9. The fire retardant roof sheeting membrane as set forth in claim 1, wherein said cure package comprises from about 0.5 to about 2 parts by weight sulfur and from about 1 to about 8 parts by weight of at least one sulfur vulcanizing accelerator.

10. The fire retardant roof sheeting membrane as set forth in claim 9, wherein said at least one sulfur vulcanizing accelerator includes a benzothiazyl disulfide.

11. The fire retardant roof sheeting membrane as set forth in claim 1, wherein the sheeting material contains about 45 percent non-combustible materials.

12. A sloped roof having an incline of at least 1 inch per linear foot, comprising the roof sheeting membrane of claim 1.

13. The fire retardant roof sheeting membrane as set forth in claim 1, wherein said membrane is scrim-reinforced.

14. A method for covering sloped roofs having an incline of at least 1 inch per linear foot comprising:

applying layers of roof sheeting material prepared from a fire retardant polymeric composition of matter to the roof being covered, said polymeric composition of matter comprising a base polymer containing at least one ethylene-propylene-diene terpolymer, said base polymer having up to about 2 percent by weight crystallinity;

from about 85 to about 175 parts by weight of at least one non-combustible mineral filler per 100 parts of said base polymer;

from about 30 to about 50 parts by weight of a processing material, per 100 parts of said base polymer;

from about 50 to about 80 parts by weight of at least one fire retardant additive, per 100 parts of said base polymer, wherein said fire retardant additive includes at least a bromine-containing additive and antimony trioxide (Sb₂O₃); and

from about 1.5 to about 10 parts by weight of a cure package per 100 parts of said base polymer;

overlapping adjacent edges of said layers; and

adhesively seaming the overlapped areas to form an acceptable seam,

said composition of matter containing at least 40 percent non-combustible materials and said sheeting material having a limiting oxygen index (LOI) of at least 40 percent oxygen when tested in accordance with ASTM D2863-91, and capable of passing the UL-790 Test for Fire Resistance of Roof Covering Materials for sloped roofs having an incline of at least 1 inch per linear foot.

15. The method as set forth in claim 14, wherein said composition of matter further comprises about 30 to 90 parts by weight of at least one black filler, per 100 parts of said base polymer.

16. The method as set forth in claim 14, wherein said at least one non-combustible mineral filler is selected from the group consisting of hard clays, soft clays, chemically modified clays, mica, talc, alumina trihydrate, calcium carbonate, titanium dioxide, amorphous precipitated hydrated silica and mixtures thereof.

17. The method as set forth in claim 14, wherein said bromine-containing additive is decabromodiphenyl oxide (DBDPO).

18. The method as set forth in claim 14, wherein said cure package comprises from about 0.5 to about 2 parts by weight sulfur and from about 1 to about 8 parts by weight of at least one sulfur vulcanizing accelerator.

19. The method as set forth in claim 18, wherein said at least one sulfur vulcanizing accelerator includes a benzothiazyl disulfide.

20. The method as set forth in claim 14, wherein said composition of matter contains about 45 percent non-combustible materials.