Cover board with honeycomb layer
AssigneeBmic LLC
InventorsJason Jones, Kenneth Lloyd Willoughby, Jr., Trieu Nguyen
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Abstract
A cover board and roofing system including a cover board are disclosed. In one embodiment, the cover board includes a honeycomb layer positioned between a first face sheet and a second face sheet. The honeycomb layer comprises a honeycomb structure having a plurality of partition walls forming a plurality of cells. When the cover board is applied as part of a roof structure, including an insulation layer and a roof deck below the cover board, the roof structure exceeds requirements for Very Severe Hail Resistance according to the FM Approvals FM 4470 VSH impact resistance testing standard for Single-Ply, Polymer-Modified Bitumen Sheet, Built-Up Roof (BUR) and Liquid Applied Roof Assemblies.
Claims17
A cover board, comprising:
- a first face sheet;
- a honeycomb layer positioned adjacent to the first face sheet, the honeycomb layer comprising a honeycomb structure formed of thermoplastic polyolefin,
- the honeycomb structure having a plurality of partition walls forming a plurality of cells;
- a second face sheet positioned such that the honeycomb layer is between the first face sheet and the second face sheet;
- and
- wherein each cell has a triangular cross-section and the honeycomb structure has a cell density of 4 to 10 cells per 10 mm2;
- wherein, when the cover board is applied as part of a roof structure including an insulation layer and a deck below the cover board, the roof structure exceeds requirements for Very Severe Hail Resistance according to FM Approvals FM 4470 VSH impact resistance testing standard for Single-Ply, Polymer-Modified Bitumen Sheet, Built-Up Roof (BUR), and Liquid Applied Roof Assemblies.
A method, comprising:
- attaching an insulation layer comprising polyisocyanurate to a deck of a roof structure;
- obtaining a cover board, the cover board comprising:
- a first face sheet;
- a honeycomb layer positioned adjacent to the first face sheet, the honeycomb layer comprising a honeycomb structure formed of thermoplastic polyolefin,
- the honeycomb structure having a plurality of partition walls forming a plurality of cells;
- a second face sheet positioned such that the honeycomb layer is between the first face sheet and the second face sheet;
- and
- wherein each cell has a triangular cross-section and the honeycomb structure has a cell density of 4 to 10 cells per 10 mm2;
- positioning the cover board over the insulation layer,
- attaching a water shedding layer to an upper surface of the cover board,
- wherein the roof structure exceeds requirements for Very Severe Hail Resistance according to FM Approvals FM 4470 VSH impact resistance testing standard for Single-Ply, Polymer-Modified Bitumen Sheet, Built-Up Roof (BUR), and Liquid Applied Roof Assemblies.
A roofing system, comprising:
- a deck,
- an insulation material positioned over the deck;
- and
- a cover board positioned over the insulation material, the cover board configured to provide severe hail resistance and comprising:
- a first face sheet;
- a honeycomb layer positioned adjacent to the first face sheet, the honeycomb layer comprising a honeycomb structure formed of thermoplastic polyolefin, the honeycomb structure having a plurality of partition walls forming a plurality of cells;
- a second face sheet positioned such that the honeycomb layer is between the first face sheet and the second face sheet;
- wherein each cell has a triangular cross-section and the honeycomb structure has a cell pitch-density of 4 to 10 cells per 10 mm2;
- wherein, when the cover board is applied as part of a roof structure including an insulation layer and a deck below the cover board, the roof structure exceeds requirements for Very Severe Hail Resistance according to FM Approvals FM 4470 VSH impact resistance testing standard for Single-Ply, Polymer-Modified Bitumen Sheet, Built-Up Roof (BUR), and Liquid Applied Roof Assemblies.
Dependencies are inferred from the claim text.