FLAME RETARDANT BUILDING CONSTRUCTION MATERIAL AND PROCESS
20210340768 · 2021-11-04
Assignee
Inventors
- Elvira Joana Ferreira Peralta (Deerfield Beach, FL, US)
- Betiana Andrea Acha (Deerfield Beach, FL, US)
- Khoa Dang (Deerfield Beach, FL, US)
- Marco Yoshua Sieber (Deerfield Beach, FL, US)
- Louis Lynn Grube (Deerfield Beach, FL, US)
Cpc classification
B32B11/02
PERFORMING OPERATIONS; TRANSPORTING
B32B5/16
PERFORMING OPERATIONS; TRANSPORTING
B32B27/12
PERFORMING OPERATIONS; TRANSPORTING
E04D12/002
FIXED CONSTRUCTIONS
B32B5/08
PERFORMING OPERATIONS; TRANSPORTING
B32B2260/042
PERFORMING OPERATIONS; TRANSPORTING
B32B2262/14
PERFORMING OPERATIONS; TRANSPORTING
B32B37/24
PERFORMING OPERATIONS; TRANSPORTING
B32B5/30
PERFORMING OPERATIONS; TRANSPORTING
B32B2307/3065
PERFORMING OPERATIONS; TRANSPORTING
E04D5/10
FIXED CONSTRUCTIONS
B32B37/156
PERFORMING OPERATIONS; TRANSPORTING
B32B5/028
PERFORMING OPERATIONS; TRANSPORTING
B32B11/10
PERFORMING OPERATIONS; TRANSPORTING
B32B2260/021
PERFORMING OPERATIONS; TRANSPORTING
B32B25/10
PERFORMING OPERATIONS; TRANSPORTING
International classification
E04D5/10
FIXED CONSTRUCTIONS
B32B11/02
PERFORMING OPERATIONS; TRANSPORTING
B32B11/10
PERFORMING OPERATIONS; TRANSPORTING
B32B37/00
PERFORMING OPERATIONS; TRANSPORTING
B32B37/24
PERFORMING OPERATIONS; TRANSPORTING
Abstract
Disclosed is a building and construction material and process including multiple layers and vermiculite ore in at least one layer. A substrate layer may have one or more layers on top or on the bottom of it. Numerous compounds may be used in one or more of the layers including asphaltic compound, polymer modified asphalt compound, thermoplastic polymer compound and others. The layers may also include synergistic flame retardant and fillers. And disclosed is a process to manufacture the building and construction material.
Claims
1. A building construction material comprising: a minimum of 2 layers; at least one compound layer: at least one substrate layer; and vermiculite ore incorporated in at least one of the layers.
2. The building construction material according to claim 1 further comprising at least one additional compound layer wherein the substrate has at least one top compound layer, and at least one bottom compound layer.
3. The building construction material according to claim 2 wherein an asphaltic compound is included in at least one layer.
4. The building construction material according to claim 2 wherein a polymer modified asphalt compound is included in at least one layer.
5. The building construction material according to claim 2 wherein a thermoplastic polymer compound is included in at least one layer.
6. The building construction material according to claim 2 wherein an elastomeric polymer compound is included in at least one layer.
7. The building construction material according to claim 2 wherein at least one layer includes a combination of at least 2 of following compounds: an asphaltic compound, a modified asphalt compound, a thermoplastic compound, an elastomeric compound.
8. The building construction material according to claim 2 wherein the vermiculite ore is deposited directly on the substrate layer.
9. The building construction material according to claim 2 wherein the building construction material has a thickness between 0.5-5.5 mm.
10. The building construction material according to claim 2 wherein the vermiculite ore is between 5-90% by weight of at least one layer.
11. The building construction material according to claim 2 wherein the vermiculite ore is incorporated into the at least one compound layer prior to incorporation into the building construction material.
12. The building construction material according to claim 2 wherein the vermiculite ore is incorporated into at the least one compound layer during a manufacturing process of the building construction material.
13. The building construction material according to claim 2 further comprising between 0-60% synergistic flame retardant in at least one layer.
14. The building construction material according to claim 2 further comprising between 0-70% filler in at least one layer.
15. The building construction material according to claim 2 wherein the vermiculite ore is between a range of 5-90% by weight of the substrate layer.
16. A process for manufacturing a building construction material comprising: selecting the building construction material comprising: a minimum of 2 layers; at least one compound layer: at least one substrate layer with a top side and a bottom side; and vermiculite ore incorporated in at least one of the layers; selecting at least one compound for each layer of the building construction material; blending one or more selected compounds including additives and fillers as desired prior to application on a manufacturing line; applying a selected compound layer onto at least one side of the substrate layer on the manufacturing line for a selected layer when the selected compound is at a desired temperature; calendaring the selected compound layer to obtain a desired thickness so that the substrate layer is at least partially saturated; applying the vermiculite ore to the selected compound layer by depositing the vermiculite ore onto the selected compound layer using an applicator; applying a surfacing as desired; and cooling, cutting, and packaging the building construction material to a desired length.
17. The process according to claim 16 that further comprises at least one side lap area.
18. The process for manufacturing a building construction material according to claim 17 that further comprises; adding compound to the side lap area; and applying a surfacing to the side lap area.
19. The process for manufacturing a building construction material according to claim 16 further comprising applying the vermiculite ore as a surfacing.
20. The process according to claim 16 wherein the vermiculite ore is added to at least one additional compound layer prior to processing on the manufacturing line.
21. The process for manufacturing a building construction material according to claim 16 further comprising adding a synergistic flame retardant in at least one selected compound layer.
22. The process for manufacturing a building construction material according to claim 16 further comprising: adding at least one additional compound layer onto the building construction material; applying at least one selected compound layer onto an opposite side of the substrate layer; calendaring the building construction material to a desired thickness; and applying a surfacing to the compound layer on the opposite side of the substrate layer.
23. The process for manufacturing a building construction material according to claim 22 further comprising applying the vermiculite ore onto at least one of the additional compound layer(s).
24. The process for manufacturing a building construction material according to claim 22 that further comprises at least one side lap area.
25. The process for manufacturing a building construction material according to claim 24 that further comprises; adding compound to the at least one side lap area; and applying a surfacing to the side lap area as desired.
26. The process for manufacturing a building construction material according to claim 22 further comprising applying the vermiculite ore as a surfacing.
27. The process for manufacturing a building construction material according to claim 22 further comprising applying the vermiculite ore to an at least one compound layer prior to processing on the manufacturing line.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DRAWING NUMBERS
[0072] 1 Top surfacing [0073] 2 Top compound layer [0074] 3 Vermiculite ore [0075] 4 Substrate [0076] 5 Bottom compound layer [0077] 6 Bottom surfacing [0078] 7 Side lap area [0079] 8 Side lap surfacing [0080] 9 Synergistic flame retardant(s) [0081] 10 Flame retardant building construction material
DETAILED DESCRIPTION
[0082] In one or more embodiments, flame retardant building construction material 10 comprises layers of thermoplastic compound, elastomeric compound, asphaltic compounds, and/or asphalt with plastomeric and/or elastomeric polymers or both to make modified bitumen based compounds as desired. Vermiculite ore 3 is incorporated in top compound layer 2 as shown in
[0083] In one or more embodiments, top compound layer 2 consists of thermoplastic compound, elastomeric compound, asphaltic compound, and/or modified bitumen compound. Top compound layer 2 may consist of one or more layers of thermoplastic, elastomeric, asphaltic, and or modified bitumen compound. Vermiculite ore 3 and or synergistic flame retardant(s) 9 can be incorporated into one or more of these layers as desired prior to application of top compound layer 2 on substrate 4 before being applied on the manufacturing line or vermiculite ore 3 can be incorporated into one or more layers of top compound layer 2 on the manufacturing line during the manufacturing process. Top compound layer 2 may also include plasticizers, oils, tackifiers, etc., and inorganic fillers like limestone, sand, ground stone dust and the like.
[0084] In one or more embodiments, substrate 4 is located between top compound layer 2 and bottom compound layer 5 as seen in
[0085] In one or more embodiments, substrate 4 can be pre-saturated with asphalt, modified bitumen and the like in one or more steps prior to application of top compound layer 2 and or bottom compound layer 5. Vermiculite ore 3 can be applied to saturated substrate 4 before top compound layer 2 and/or bottom compound layer 5 is applied on the production line in one or more layers as desired. Alternately, substrate 4 can be saturated with top compound and or bottom compound during the manufacturing process on the production line. Sometimes Substrate 4 is used as top surfacing 1 and one or more thermoplastic, elastomeric, asphaltic and or modified bitumen compound layers are used for bottom compound 5 to make flame retardant building construction material 10.
[0086] In one or more embodiments, optional top surfacing 1 located on top compound layer 2 covers essentially the entire area of top compound layer 2 as seen in
[0087] In one or more embodiments, bottom compound layer 5 consists of one or more layers of thermoplastic compound, elastomeric compound, asphalt based compound or asphalt modified with plastomeric and/or elastomeric polymers or both and may include plasticizers, oils, tackifiers, etc., and inorganic fillers like limestone, sand, ground stone dust and the like. Bottom compound layer 5 may consist of one or more layers of asphalt and or modified bitumen compound or both. One or more layers of bottom compound 5 may also be a self-adhered or self-sealing compound for use in what is commonly called in the industry as self-adhered, peel and stick, and or thermally activated applications.
[0088] In one or more embodiments, top compound layer 2 and bottom compound layer 5 may comprise the same compound, i.e. asphaltic, plastomeric and/or elastomeric compound, or top compound layer 2 and bottom compound layer 5 may be entirely different compounds. Also one or more layers of thermoplastic, elastomeric, asphalt and or modified bitumen compound or both can comprise top compound layer 2 and/or bottom compound layer 5. Vermiculite ore 3 and/or synergistic flame retardant(s) 9 can be used as desired in one or more of these compound layers as seen in
[0089] It should be noted that the compound layers that comprise top compound layer 2 and the compound layers that comprise bottom compound layer 5 in
[0090] In one or more embodiments, bottom surfacing 6 located below bottom compound layer 5 as seen in
[0091] In one or more embodiments, flame retardant building construction material 10 incorporates a side lap area 7 with side lap surfacing 8 located on top of side lap area 7 adjacent to top surfacing 1 on top compound layer 2 as seen in
[0092] Side lap area 7 is about 2-5 inches in width and typically runs along the edge of flame retardant building construction material 10. Side lap area 7 is intended to be an area essentially free from top surfacing 1 and is an area designated by the manufacturer for adhering together the overlying flame retardant building construction material to the underlying flame retardant building construction material.
[0093] In one or more embodiments, side lap surfacing 8 can comprise a polymeric film with or without a release agent like silicone, a paper release liner treated with a release agent like silicone, an exposed second substrate partially embedded into top compound layer 2, sand, talc, mica and the like.
[0094] In one or more embodiments, the compound in a side lap area 7 is the same asphaltic based compound type used to construct top compound 2 for ease of manufacturing. Sometimes an adhesive is applied in a side lap area 7 to enhance the bond with bottom compound layer 5 when the flame retardant building construction material is overlapped. In one or more embodiments, synergistic flame retardant 9 like Colemanite, Aluminum Trihydrate, Magnesium hydroxide, expanded vermiculite, expandable graphite, and the like, used alone and or in combinations thereof to name a few, can be used without vermiculite ore 3 in bottom compound layer 5 as seen in
[0095] In one or more embodiments, synergistic flame retardant 9 is used in combination with vermiculite ore 3 in top compound layer 2 without additional flame retardant(s) being used in bottom compound layer 5 as seen in
[0096] Synergistic flame retardant 9 is typically added to top compound layer 2 prior to using top compound 2 as a layer on the production line. Vermiculite ore 3 used in top compound 2 as seen in
[0097] In other examples, synergistic flame retardant 9 and vermiculite ore 3 are incorporated into top compound layer 2 and synergistic flame retardant 9 is also added to bottom compound layer 5 as seen in
[0098] In one or more embodiments, vermiculite ore 3 used in top compound layer 2 can be added to top compound 2 along with synergistic flame retardant 9 prior to top compound layer 2 being applied on the production line or vermiculite ore 9 can be added to top compound 2 on the production line prior to adding top surfacing 1 to flame retardant building construction material 10.
[0099] In other examples, vermiculite ore 3 and synergistic flame retardant 9 are added to top compound layer 2 and also to bottom compound layer 5 of flame retardant building construction material 10 as seen in
[0100] In the examples listed above, top compound layer 2 may consist of one or more asphaltic based compound layers and bottom compound 5 may consist of one or more layers of asphaltic based compound. Top compound layer 2 and/or bottom compound layer 5 may be comprised of the same type and composition, i.e. asphaltic compound(s), plastomeric and/or elastomeric modified bitumen compound(s) or combination thereof. Also top compound layer 2 and bottom compound layer 5 may be the same type of compound(s) but with different formulations or top compound layer 2 and bottom compound layer 5 may be different types of compound(s) and compositions entirely.
[0101] The disclosed flame retardant building construction material in these embodiments and examples is focused primarily on the use of vermiculite ore incorporated in the flame retardant building construction material with or without synergistic flame retardant(s) in one way or another. A preferred way to use the vermiculite ore is in the top compound layer alone. Alternate preferred methods include using the vermiculite ore with or without synergistic flame retardant(s) in either the top compound layer or layers or the bottom compound layer or layers or used in multiple compound layers as desired. The use of vermiculite ore is of importance and is the novel idea being disclosed and not the type of compound used or the use of other materials and/or other ingredients used in the formula to manufacture the flame retardant building construction material.
[0102] The vermiculite ore disclosed in the examples is a naturally occurring mineral that expands when heated. Technically, vermiculite ore encompasses a large group of hydrated laminar magnesium-aluminum-iron silicates, which resemble mica. There are two keys to the unique properties of vermiculite. The first is its laminar (or layered) crystalline structure, which provides the hinged plates that make the material expand or unfold in a linear manner. The second is the fact that it contains trapped water, which flashes into steam when heated to force the layers open. It has been discovered that when the vermiculite ore is at a certain critical concentration, the vermiculite ore fuses, forming a crystal like continuous layer when exposed to temperatures of 1200° C. or higher, when used alone or in combination with other inorganic or organic materials and/or compounds. The release of trapped water combined with the crystalline layer structure gives vermiculite its flame retardant characteristics.
[0103] The vermiculite ore used in the embodiments and examples is added to and/or incorporated into thermoplastic, elastomeric, asphaltic and or modified bitumen compounds to make flame retardant building construction materials with or without a synergistic flame retardant like Colemanite. When these flame retardant building construction materials are tested by Underwriters Laboratory (UL) using the UL 790 (ASTM E-108) test method they pass a Class A rating that is the highest rating obtainable over combustible and noncombustible decks. It was observed during testing of the disclosed flame retardant building construction material by using the UL 790 test method that the vermiculite ore released trapped water and formed a protective crust like shield over the surface of the flame retardant building construction material that prevented the flames from spreading and penetrating the flame retardant building construction material.
[0104] The flame retardant building construction material disclosed can be used anywhere on a building structure, on the top or side of a building or roof deck alone or in combination with other building construction materials, it can be used as an underlayment under other roofing, siding, flooring and building envelope materials including metal panels, tiles and the like or as a final roof, siding, blindside waterproofing, floor and/or building envelope covering alone to name a few.
[0105] The vermiculite ore used in the disclosed flame retardant building construction material is also identified as untreated vermiculite with a CAS-No. 1318-00-9. It has a specific gravity between 2 and 3 with a preferred specific gravity between 2.4 and 2.8, a bulk density between 40-60 lbs/ft.sup.3 (640-1041 Kg/m.sup.3) and a pH of 6-8. The vermiculite ore also has a granulometry or sieve grading between 0.1 and 2.4 mm as seen in Table 1 below. It should be noted that all 3 grades of vermiculite ore shown in Table 1 are viable examples that have been and can be used in the disclosed flame retardant building construction material with or without a synergistic flame retardant(s) that passed UL 790 flame testing to achieve the Class A, B or C ratings as desired for the disclosed flame retardant building construction material. The use of a finer particle size and/or ground vermiculite ore is also incorporated in this disclosure.
TABLE-US-00001 TABLE 1 % Weight Retained on each screen Vermiculite Grade U.S. Screens mm VCX 203 VCX 204 VCX 205 8 2.36 — — — 12 1.70 0-10 — — 16 1.18 10-35 — — 20 0.85 25-40 — — 30 0.60 20-40 — 0-1 40 0.425 2-14 24-40 — 50 0.30 0-8 24-38 0-20 70 0.212 0-7 10-20 — 100 0.15 — 0-15 30-76 −100 pan <0.15 — — —
[0106] The sieve size of the vermiculite ore used is typically larger than other inorganic fillers and flame retardants used for similar purposes in thermoplastic, elastomeric, asphaltic, and or modified bitumen flame retardant building construction materials. This larger size limits the amount one can add to the compound prior to processing the material on the production line. Limestone used for a filler for example is much finer and typically most if not all of the limestone will pass through a 100 US sieve and has been used in amounts up to 75% in asphaltic shingle products. Colemanite that is also much finer than the disclosed unexpanded vermiculite for example and also typically passes completely through a US 100 sieve has been used in compounds up to 50% in flame retardant building construction materials as disclosed by Grube et al., in U.S. Pat. No. 5,055,135.
[0107] The vermiculite ore with a sieve grading greater than a US 100 sieve size grading used in the disclosed flame retardant building construction material can be added from about 5-55% by weight to various compounds like asphaltic or modified bitumen compound prior to processing the compound on the production line with or without additional synergistic flame retardants, with or without other inorganic fillers and additives like oils, tackifiers, polymers etc. and pass the UL Class A fire rating.
[0108] It has been discovered in a preferred embodiment that adding the vermiculite ore to the hot thermoplastic compound, hot elastomeric compound, hot asphaltic compound, or hot modified bitumen compounds during manufacturing of the flame retardant building construction material on the production line is the preferred and easiest way to process the vermiculite ore into the flame retardant building construction material. The vermiculite ore has a high specific gravity and when dropped from above using a standard sand or granule applicator prior to and/or after the addition of one or more top surfacing layers, allows the vermiculite ore to sink into the compound to various degrees depending on the height of the applicator, the temperature of the compound and the thickness of the compound it is applied onto.
[0109] The preferred process for manufacturing flame retardant building construction material 10 using vermiculite ore 3 incorporated into the flame retardant building construction material 10 is as follows: [0110] 1. Blend and make compound(s) as needed for flame retardant building construction material 10 as is normally done in production including additives and fillers as desired prior to application on the manufacturing line. [0111] 2. Add optional synergistic flame retardant(s) 9 to compound(s) as desired and mix until incorporated. [0112] 3. Transfer compound(s) to the production line when compound(s) is at the desired temperature(s) and use the compound(s) as part of or as the entire top compound layer 2, or in part of or as the entire bottom compound layer 5 or in both top and bottom compound layers as desired. [0113] 4. The hot compound(s) with or without optional synergistic flame retardant(s) 9 are applied in layers as desired to substrate 4 in one or more steps and is calendared or scraped to saturate substrate 4 and obtain a desired thickness. [0114] 5. Vermiculite ore 3 is then applied to the hot top compound layer 2 on saturated substrate 4 by dropping and depositing vermiculite ore 3 onto hot top compound layer 2 using a standard applicator for applying sand and or granules to a construction material. [0115] 6. Additional layer(s) of top compound layer 2 with or without optional synergistic flame retardant(s) 9, can be applied onto previously applied top compound layer 2 as desired. [0116] 7. Vermiculite ore 3 can be dropped onto additional top compound layer(s) 2 as desired or used as top surfacing 1. [0117] 8. Bottom compound layer(s) 5 with or without synergistic flame retardant(s) 9, with or without vermiculite ore 3, is applied to the bottom of substrate 4. [0118] 9. Flame retardant building construction material 10 is calendared to the desired thickness. [0119] 10. Side lap adhesive, compound, and/or self-adhered compound can be applied in optional side lap area 7. [0120] 11. Optional top surfacing 1 and optional side lap surfacing 8 can be applied to the top compound layer 2 as desired. [0121] 12. Bottom surfacing 6 is applied as desired to the bottom compound layer 5. [0122] 13. Flame retardant building construction material 10 is cooled and cut to the desired length and packaged as desired.
[0123] The processes mentioned above can be altered by adding vermiculite ore 3 to the compound(s) prior to manufacturing on the production line. The disclosed process serves only as a guideline in order to manufacture the disclosed flame retardant building construction material 10. Alterations to the process are incorporated herein to maintain the spirit of the disclosed invention.
[0124] Also, vermiculite ore 3 can be used as top surfacing 1 or bottom surfacing 6 as desired alone or with other surfacings or become incorporated into flame retardant building construction material 10 in the manner described above prior to adding a top or bottom surfacing like a polymeric film for example. It has been discovered that up to 90% by weight of vermiculite ore can be dropped onto the hot asphalt and/or modified bitumen compound(s) on the production line for the desired compound layer.
[0125] Vermiculite ore at a preferred weight percent of 10-60% can be used in a single compound layer with or without a synergistic flame retardant(s) for the flame retardant building construction material and pass UL 790 Class A fire rating.
[0126] The vermiculite ore can be dropped onto one or more compound layers as desired or needed. For example, the vermiculite ore can be dropped across the entire top compound layer or entire bottom compound layer or both compound layers. In another example the vermiculite ore can be dropped onto the desired compound layer(s) in distinct strips, bands, zones, and or sections. In yet another example the vermiculite ore can be dropped onto the top compound layer without dropping the vermiculite ore in the side lap area of the top compound layer.
[0127] The amount of vermiculite ore dropped onto the compound layer can vary depending on several factors including: [0128] 1. Amount of optional vermiculite ore added to the compound or compounds prior to processing the compound(s) on the production line for use in one or more compound layers to manufacture the flame retardant building construction material. [0129] 2. Amount of optional synergistic flame retardant(s) added to the compound or compounds prior to processing the compound(s) on the production line for use in one or more compound layers to manufacture the flame retardant building construction material. [0130] 3. Amount of optional vermiculite ore and amount of optional synergistic flame retardant added alone or together to the compound or compounds prior to processing the compound(s) on the production line for use in one or more compound layers to manufacture the flame retardant building construction material.
[0131] In one embodiment, it has been discovered that a single layer of a flame retardant building construction material or membrane under steel metal panels, tiles, shingles, or the like can be used as a combined flame barrier and water and/or vapor and/or air barrier, achieves a Class A fire rating as tested by UL 790 criteria. The single ply of the flame retardant building construction material or membrane used to pass the UL 790 Class A fire testing has a total thickness of 1.0-3.5 mm, with a preferred total thickness of 2.0-2.5 mm, uses 10-90% by weight of vermiculite ore in the top compound layer only, uses a tacky self-adhered elastomeric bottom compound layer at a thickness of 0.2-0.6 mm, with a preferred bottom compound thickness layer of 0.3-0.5 mm, without synergistic flame retardant(s) used in either the top or bottom compound layer(s) to make the flame retardant building construction material or membrane.
[0132] The top compound layer with vermiculite ore, with or without added synergistic flame retardant(s), acts as the flame barrier. The tacky elastomeric self-adhered bottom compound layer, with or without added synergistic flame retardant(s), is used for the vapor and/or water and/or air barrier. This single ply flame retardant building construction material or membrane protects the structure from fire, vapor, air, and water intrusion.
[0133] For example, the single ply flame retardant building construction material or membrane used to pass UL Class A 790 fire tests under metal panels comprises a glass mat as the substrate, a polymeric film as a top surfacing and a release liner treated with silicone as the bottom surfacing that is removed prior to installation.
[0134] The need for additional flame retardants in the top compound layer or subsequent compound layers can be reduced and or eliminated since a large percentage of vermiculite ore can be dropped onto the desired compound layer(s) during manufacturing. This simplifies the manufacturing of flame retardant building construction materials or membranes that need to achieve a fire rating classification like UL 790 Class A, B, or C fire rating. These fire ratings are often desired by building owners and are often required by code bodies in the industry.
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[0136] The amount of vermiculite ore used with or without synergistic flame retardant(s) in one or more layers in the flame retardant building construction material to obtain a UL 790 Class A, B, or C fire test rating, will vary by how and what the flame retardant building construction material is used for, how many layers of material is desired, what the manufacturers' warranty calls for, and if the deck or structure is combustible or if the deck or structure is non-combustible to name a few.
[0137] The flame retardant building construction materials disclosed in Drawings 1-26, range in thickness from 0.5-5.5 mm and can be produced easily and economically as described previously. Guideline examples for the manufacturing of flame retardant building construction materials or membranes using vermiculite ore with or without synergistic flame retardants is listed below. It should be noted that the top compound layer 2 is defined as the layer or layers located above substrate 4 or carrier used to move the material through a production line, bottom compound layer 5 is defined as the layer or layers located below substrate 4 or carrier used to move the material through the production line. Also, some flame retardant building construction materials may have single or multiple compound layers located only above the substrate or carrier and some flame retardant building construction materials may have single or multiple compound layers located only below the substrate or carrier. These flame retardant building construction materials are incorporated herein.
[0138] Examples for those trained in the art that compound and manufacture fire retardant building construction materials, these ranges are included as a starting point guideline but are not limited to: [0139] 1. 10-90% by weight of vermiculite ore in top compound layer without synergistic flame retardant(s) being used in any layer as demonstrated in
[0151] Fire resistant building construction materials or membranes that use vermiculite ore as a flame retardant, with or without synergistic flame retardant(s), in one or more compound layers, is easy to manufacture, is lower in cost compared to traditional flame retardants currently used in the industry, is environmentally friendly and is an economical and environmentally friendly solution to the problems stated previously. The use of vermiculite ore, with or without synergistic flame retardant(s), used alone in one compound layer, further reduces the overall cost of the flame resistant building construction material or membrane and can achieve a UL 790 Class A rating in various roof systems including under a metal panel roof in a single layer as one example.
[0152] In one embodiment the building construction material includes a minimum of 2 layers including at least one compound layer and one substrate or carrier layer, with vermiculite ore incorporated in at least one of the layers.
[0153] In another embodiment the building construction material includes a second compound layer with one compound layer is a top layer and one compound layer is a bottom compound layer with vermiculite ore incorporated in at least one of the layers.
[0154] Many other embodiments are possible related to the material used in the layers of the building construction material. For example, one or more of these compounds can be used: an asphaltic compound, a polymer modified asphalt compound, a thermoplastic polymer compound, an elastomeric polymer compound.
[0155] In another embodiment at least one layer can include a combination of at least 2 of the following compounds: an asphaltic compound, a modified asphalt compound, a thermoplastic compound, an elastomeric compound.
[0156] The vermiculite ore can be added into one or more layers prior to incorporation into the building construction material. Or the vermiculite ore can be added into one or more layers during the manufacturing process of the building construction material.
[0157] The vermiculite ore can be deposited directly on the substrate.
[0158] One embodiment of the process to create the disclosed building construction material includes:
selecting a building construction material comprising: a minimum of 2 layers, at least one compound layer, at least one substrate layer, and vermiculite ore incorporated in at least one of the layers;
selecting the number of layers to be incorporated into the building construction material;
selecting at least one compound for each layer of the building construction material;
selecting a substrate that has a top side and a bottom side;
blending one or more selected compounds including additives and fillers as desired prior to application on a manufacturing line;
deciding if a synergistic flame retardant will be included into at least one selected compound and mixing selected synergistic flame retardant until incorporated into the selected compound;
applying selected compound onto at least one side of the substrate on the manufacturing line for a selected layer when the selected compound is at a desired temperature;
calendaring the selected compound layer to obtain a desired thickness so that the substrate is at least partially saturated;
applying vermiculite ore to the selected compound layer by depositing vermiculite ore onto the selected compound layer using an applicator;
applying a surfacing as desired; and
cooling, cutting, and packaging the building construction material to a desired length.
[0159] Another embodiment of the process to create the disclosed building construction material includes adding compound to the side lap area; and applying a surfacing to the side lap area. The vermiculite ore can also be applied as a surfacing. And the vermiculite ore can be added to additional compound layers prior to processing on the manufacturing line.
[0160] Another embodiment of the process to create the disclosed building construction material further includes: adding at least one additional layer onto the building construction material; applying a selected compound layer onto an opposite side of the substrate;
calendaring the building construction material to saturate the substrate to a desired thickness; and applying a surfacing to compound layer on the opposite side of the substrate layer.
[0161] Vermiculite ore can also be applied to at least one more additional compound layer. In one embodiment the process for manufacturing a building construction material according to includes adding a compound layer to at least one side lap area; and applying a surfacing to the side lap area as desired.
[0162] The process can include applying the vermiculite ore as a surfacing. And the vermiculite ore can be applied to at least one compound layer prior to processing on the manufacturing line. Having described preferred embodiments which serve to illustrate various concepts, structures and techniques which are the subject of this patent, it will now become apparent to those of ordinary skill in the art that other embodiments incorporating these concepts, structures, and techniques may be used. Accordingly, it is submitted that that scope of the patent should not be limited to the described embodiments but rather should be limited only by the spirit and scope of the following claims.