# US 2023/0064072 A1 · Cover board with honeycomb layer > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2023/0064072 A1 - Document ID: US20230064072A1 - Status: Published application - Kind: A1 - Application number: 17/894,553 - Filed: 2022-08-24 - Published: 2023-03-02 - Earliest claimed: 2021-08-25 - Assignees: Bmic LLC - Applicants: Bmic LLC - Inventors: Jason Jones; Kenneth Lloyd Willoughby, Jr.; Trieu Nguyen - Web page: https://patentgrep.com/patent/US20230064072A1 ## CPC - 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) - 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} - B32B 3/12: characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure - B32B 7/02: Physical, chemical or physicochemical properties - B32B 7/08: by mechanical means - B32B 7/12: using interposed adhesives or interposed materials with bonding properties - B32B 15/085: comprising polyolefins - B32B 15/088: comprising polyamides - B32B 15/12: of paper or cardboard - B32B 17/061: {of metal} - B32B 17/066: {of foam} - B32B 17/10: of synthetic resin - B32B 27/08: of synthetic resin - B32B 27/10: of paper or cardboard - B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)} - B32B 27/34: comprising polyamides - B32B 27/365: {comprising polycarbonates} - E04D 12/002: {Sheets of flexible material, e.g. roofing tile underlay} - E04D 13/1681: {Insulating of pre-existing roofs with or without ventilating arrangements} - B32B 2250/03: 3 layers - B32B 2250/40: Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA - B32B 2307/558: Impact strength, toughness - B32B 2307/712: Weather resistant - B32B 2307/7265: Non-permeable - B32B 2307/73: Hydrophobic - B32B 2307/732: Dimensional properties - B32B 2419/06: Roofs, roof membranes - 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 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. ## Claims ### Claim 1 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 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, 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. ### Claim 2 (depends on 1) The cover board of claim 1, wherein each of the plurality of cells comprise a triangular, quadrilateral, pentagonal, hexagonal, heptagonal, or octagonal cross-section. ### Claim 3 (depends on 1) The cover board of claim 1, wherein the honeycomb layer comprises a thickness of 2 mm to 30 mm, and wherein the first face sheet and the second face sheet each comprise a glass, polymer or paper sheet having a thickness of approximately 20 mils to 100 mils. ### Claim 4 (depends on 1) The cover board of claim 1, wherein the first face sheet and the second face sheet each comprise a paper, glass, a thermoplastic polyolefin, a polycarbonate, a polypropylene, a polyaramid, or a polyethylene. ### Claim 5 (depends on 1) The cover board of claim 1, wherein the honeycomb structure comprises a density of 1 cell to 10 cells per 10 mm2. ### Claim 6 (depends on 1) The cover board of claim 1, wherein the cover board comprises a flexible sheet adapted to be applied over the insulation layer at a site of installation of the roof structure. ### Claim 7 (depends on 1) The cover board of claim 1, wherein the honeycomb layer comprises a thermoplastic polyolefin, a polycarbonate, a polypropylene, a polyaramid, a polyethylene, metal, or a combination thereof. ### Claim 8 (depends on 1) The cover board of claim 1, wherein each of the plurality of cells further comprises a chamber defined by the walls of each cell. ### Claim 9 (depends on 8) The cover board of claim 8, wherein the chamber of each cell is at least partially filled with a foam, solid, flexible, or resilient material, or combination thereof. ### Claim 10 (depends on 1) The cover board of claim 1, wherein at least one of the first face sheet and second face sheet comprise a polymer membrane material configured to provide water shedding and resistance to water-ponding. ### Claim 11 A method, comprising: attaching an insulation layer comprising polyisocyanurate to a deck of a roof structure; positioning a cover board over the insulation layer, 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 having a plurality of partition walls forming a plurality of cells; and a second face sheet positioned such that the honeycomb layer is between the first face sheet and the second face sheet; and 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. ### Claim 12 (depends on 11) The method of claim 11, further comprising attaching a membrane layer over the insulation layer prior to positioning the cover board over the insulation layer. ### Claim 13 (depends on 11) The method of claim 11, further comprising attaching the cover board to the insulation layer by adhesive, laminating, welding, fasteners, or combinations thereof. ### Claim 14 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 very 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 having a plurality of partition walls forming a plurality of cells, and a second face sheet positioned such that the honeycomb layer is between the first face sheet and the second face sheet, wherein the roofing system 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. ### Claim 15 (depends on 14) The roofing system of claim 14, further comprising an underlayment positioned over the insulation material and below the cover board, the underlayment comprising a polymer membrane configured to provide resistance to migration of water therethrough. ### Claim 16 (depends on 14) The roofing system of claim 14, wherein the cover board is attached over the insulation material by an adhesive, lamination, welding, a mechanical connection, or a combination thereof. ### Claim 17 (depends on 14) The roofing system of claim 14, wherein the insulation material comprises a layer of polyisocyanurate foam. ### Claim 18 (depends on 14) The roofing system of claim 14, wherein the first face sheet and second face sheet each comprise a face sheet formed from paper, glass, plastic, polymer, or combination thereof. ### Claim 19 (depends on 14) The roofing system of claim 14, wherein each of the cells of the plurality of cells comprises a chamber, and further comprising a foam, solid, flexible, resilient material, or a combination thereof received within the chambers of at least a portion of the cells of the plurality of cells. ### Claim 20 (depends on 14) The roofing system of claim 14, wherein the honeycomb layer comprises a thermoplastic polyolefin, a polycarbonate, a polyaramid, a polyethylene, a metal, or a combination thereof.