# US 12,180,715 B2 · Commercial roofing specifically in the area of roofing insulation and coverboards

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- Number: US 12,180,715 B2
- Document ID: US12180715B2
- Status: Granted
- Kind: B2
- Application number: 17/851,894
- Filed: 2022-06-28
- Published: 2023-12-28
- Granted: 2024-12-31
- Earliest claimed: 2022-06-28
- Assignees: Johns Manville
- Applicants: Johns Manville
- Inventors: Jonas Houchin; Richard Barnes
- Web page: https://patentgrep.com/patent/US12180715B2

## CPC

- E04D 3/352: {at least one insulating layer being located between non-insulating layers, e.g. double skin slabs or sheets}
- B32B 37/18: involving the assembly of discrete sheets or panels only
- E04D 13/1606: {Insulation of the roof covering characterised by its integration in the roof structure (self-supporting insulating slabs E04B7/22, E04B7/225)}
- E04D: ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS (coverings of outer walls by plaster or other porous material E04F13/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM

## Abstract

A method of manufacturing a conductive roofing board may include pouring a polyisocyanurate foam on top of a facer. The method may include laminating the polyisocyanurate foam and the facer to cure the polyisocyanurate foam and adhere the polyisocyanurate foam to the facer to form a roofing board. The method may include applying a conductive coating to an exposed surface of the facer, wherein the conductive coating has a coating weight of between about 0.1 lb/100 sqft and 10 lb/100 sqft. The method may include exposing the roofing board and the conductive coating to a heating device to cure the conductive coating.

## Claims

### Claim 1

A method of manufacturing a conductive roofing board, comprising:
pouring a polyisocyanurate foam on top of a facer;
laminating the polyisocyanurate foam and the facer to cure the polyisocyanurate foam and adhere the polyisocyanurate foam to the facer to form a roofing board;
applying a conductive coating to an exposed surface of the facer, wherein the conductive coating has a coating weight of between about 0.1 lb/100 sqft and 10 lb/100 sqft; and
exposing the roofing board and the conductive coating to a heating device to cure the conductive coating.

### Claim 2 (depends on 1)

The method of manufacturing the conductive roofing board of claim 1, wherein:
the conductive coating comprises one or more selected from the group consisting of carbon black, graphite, carbon fibers, graphene, steel fibers, and carbon nanotubes.

### Claim 3 (depends on 1)

The method of manufacturing the conductive roofing board of claim 1, wherein:
the facer comprises one or both of a nonwoven glass mat facer or a paper facer.

### Claim 4 (depends on 1)

The method of manufacturing the conductive roofing board of claim 1, wherein:
the conductive coating is applied with a coating uniformity of at least about 90% across a surface area of the facer.

### Claim 5 (depends on 1)

The method of manufacturing the conductive roofing board of claim 1, wherein:
applying the conductive coating comprises one or both of roll coating and spray coating the conductive coating onto the facer.

### Claim 6 (depends on 1)

The method of manufacturing the conductive roofing board of claim 1, wherein:
applying the conductive coating comprises coating a downward-facing surface of the facer.

### Claim 7 (depends on 1)

The method of manufacturing the conductive roofing board of claim 1, wherein:
the conductive coating has a resistance level of between about 1×102 and 1×107 ohms per square.

### Claim 8 (depends on 1)

The method of manufacturing the conductive roofing board of claim 1, wherein:
the conductive coating saturates an interior region of the facer.

### Claim 9

A method of manufacturing a conductive roofing board, comprising:
providing a roofing board, wherein the roofing board comprises:
a roofing board substrate comprising at least one of a polyisocyanurate foam board, an oriented strand board, a wood fiber board, a plywood board, or a gypsum board;
a facer applied to an outer surface of the roofing board substrate, the facer comprising one or both of paper and a nonwoven glass mat; and
applying a conductive coating to an exposed surface of the facer at a coating weight of between about 0.1 lb/100 sqft and 10 lb/100 sqft.

### Claim 10 (depends on 9)

The method of manufacturing the conductive roofing board of claim 9, wherein:
the conductive coating is applied directly to a first major surface of the roofing board substrate.

### Claim 11 (depends on 2)

The method of manufacturing the conductive roofing board of claim 2, wherein:
applying the conductive coating further comprises applying the conductive coating to the outer surface of the roofing board; and
the method further comprises exposing the roofing board and the conductive coating to a heating device to cure the conductive coating.

### Claim 12 (depends on 9)

The method of manufacturing the conductive roofing board of claim 9, wherein:
a coating uniformity of the conductive coating is at least 90%.

### Claim 13 (depends on 9)

The method of manufacturing the conductive roofing board of claim 9, wherein:
applying the conductive coating comprises pouring polyisocyanurate foam onto a facer that comprises the conductive coating.