ROOFING SYSTEM

Abstract

A roofing system and method of installing a roofing system can include a roof deck with first and second layers applied over the roof deck, and with a membrane applied thereover. The first and second layers can comprise insulation materials, with at least one of the first and second layers including a reinforced insulation material comprising a substrate with a reinforcing sublayer integrated therewith. The reinforcing sublayer can define an upper surface of the reinforced insulation material. The roofing system is configured to resist impacts from hail and other objects without a coverboard.

Claims

1. A roofing system, comprising: a roof deck; a first layer positioned above the roof deck, the first layer comprising a first insulation material; a second layer positioned above the first layer, the second layer comprising: a substrate comprising a second insulation material; and a reinforcing sublayer integrated with the substrate defining an upper surface of the second layer opposite the first layer; and wherein the reinforcing sublayer comprises a fiber reinforced polymer composite material; a membrane positioned above the upper surface of the second layer; wherein the roofing system does not include a separate coverboard layer between the second layer and the membrane.

2. The roofing system of claim 1, further comprising an adhesive applied between the membrane and the upper surface of the second layer and configured to attach the membrane to the fiber reinforced polymer composite material of the reinforcing sublayer.

3. The roofing system of claim 1, wherein the second layer is configured to provide a resistance cracking upon impact of an object thereagainst such that the roofing system exceeds requirements for Very Severe Hail Resistance according to ls FM 4473 VSH Impact Resistance Testing Standard for Impact Resistance Testing Standard for Impact Resistance Testing of Rigid Roofing Materials by Impacting with Freezer Ice Balls.

4. The roofing system of claims 1, wherein the fiber reinforced polymer composite material comprises a plurality of glass fibers, fiberglass fibers, carbon fibers, natural fibers, or a combination thereof, and a resin.

5. The roofing system of claim 4, wherein the resin comprises a polymer, a biodegradable material, low-carbon footprint material, or a combination thereof.

6. The roofing system of claim 1, wherein the fiber reinforced polymer composite material comprises a skin having a thickness of 1 mm to 8 mm.

7. The roofing system of claim 1, wherein the fiber reinforced polymer composite comprises a sheet material molded composite including a plurality of glass fibers, fiberglass fibers, carbon fibers, natural fibers, or a combination thereof, mixed with a sheet molding compound.

8. The roofing system of claim 1, wherein the second layer further comprises a base sheet adhered to the upper surface of the second layer, the base sheet comprising a modified bitumen material.

9. The roofing system of claim 1, further comprising a layer of a vapor retardant material positioned between the roof deck and the first insulation layer.

10. The roofing system of claim 1, wherein the membrane comprises a two-ply modified bitumen material including a base sheet comprising a bituminous asphalt material and a cap sheet applied over the base sheet and comprising a polymeric material.

11. The roofing system of claim 1, wherein the membrane comprises at least one of a thermoplastic polyolefin, an ethylene propylene diene monomer, polyvinyl chloride, or a modified bitumen material.

12. The roofing system of claim 1, wherein the first insulation material and the second insulation material each comprise polyisocyanurate, mineral wool, expanded polystyrene foam, extruded polystyrene foam, or a combination thereof.

13. The roofing system of claim 1, wherein the first layer comprises a thickness of 1 inch to 3.65 inches; and the second layer comprises a thickness of 1 inch to 3.75 inches.

14. The roofing system of claim 1, wherein the first insulation layer and the second insulation layer together are configured to provide a resistance to conductive heat flow through the roofing system having an R-value of at least R30; and further comprising a third insulation layer comprising an additional insulation material positioned along the first insulation layer; wherein the third insulation layer is configured to increase the resistance to conductive heat flow of the roofing system such that the roofing system has an overall resistance to conductive heat flow that is greater than an overall resistance to conductive heat flow of a roofing system including a coverboard.

15. The roofing system of claim 1, wherein the second layer further comprises an additional reinforcing sublayer attached to a lower surface of the substrate; wherein the additional reinforcing sublayer comprises a fiber reinforced material that is different from the fiber reinforced polymer composite material positioned along the upper surface of the substrate.

16. The roofing system of claim 1, wherein the first insulation layer has a first thickness, and the second insulation layer has a second thickness that is greater than the first thickness of the first insulation layer; and wherein the roofing system has a thickness substantially equal to or less than a thickness of a roofing system including a coverboard.

17. The roofing system of claim 1, further comprising at least one sensor coupled to the second insulation layer.

18. The roofing system of claim 1, wherein the membrane comprises at least one of a thermoplastic polyolefin, an ethylene propylene diene monomer, polyvinyl chloride, or a modified bitumen sheet.

19. A package comprising: a plurality of insulation panels including reinforced insulation panels; wherein each of the reinforced insulation panels comprises: a substrate; and a reinforcing sublayer laminated to, attached to, extruded with or molded with the substrate so as to be integrated with the substrate, wherein the reinforcing sublayer comprises a fiber reinforced polymer composite material; wherein the reinforced insulation panels are configured to provide a resistance to cracking upon impact of an object thereagainst such that when the reinforced insulation panels are included as part of a roofing system having a first layer of insulation panels positioned along a roof deck, a second layer of the reinforced insulation panels above the first layer of insulation panels, a membrane applied over an upper surface of each of the reinforced insulation panels, and without a coverboard positioned between the membrane and the reinforced insulation panels, the roofing system exceeds requirements for Very Severe Hail Resistance according to FM 4473 VSH Impact Resistance Testing Standard for Impact Resistance Testing Standard for Impact Resistance Testing of Rigid Roofing Materials by Impacting with Freezer Ice Balls.

20. The package of claim 19, wherein the reinforced insulation panels further comprise an additional reinforcing sublayer attached to a lower surface of the substrate; wherein the additional reinforcing sublayer comprises a fiber reinforced material that is different from the fiber reinforced polymer composite material positioned along the upper surface of the substrate.

21. The package of claim 19, wherein the substrate comprises polyisocyanurate, mineral wool, expanded polystyrene foam, extruded polystyrene foam, or a combination thereof.

22. The package of claim 19, wherein the fiber reinforced polymer composite material comprises a plurality of glass fibers, fiberglass fibers, carbon fibers, natural fibers, or a combination thereof, and a resin molded or extruded to form the fiber reinforced material.

23. The package of claim 19, further comprising a modified bitumen layer configured to attach to an upper surface of each reinforced insulation panel.

24. The package of claim 19, wherein the reinforced insulation panels each further comprise a membrane attached to an upper surface thereof; wherein the membrane comprises a two-ply modified bitumen material including base sheet attached to the fiber reinforced polymer composite material and comprising a bituminous asphalt material, and a cap sheet applied over the base sheet and comprising a weather resistant polymeric material.

25. The package of claim 23, further comprising an adhesive adapted to attach the modified bitumen layer to the reinforcing sublayer of each reinforced insulation panel.

26. The package of claim 19, wherein the reinforced insulation panels each comprise a thickness of 1 inch to 3.75 inches; and wherein the reinforcing sublayer comprises a thickness of 1 mm to 8 mm.

27. The package of claim 19, wherein one or more of the reinforced insulation panels include at least one sensor.

28. The package of claim 27, wherein the at least one sensor comprises one or more sensors adapted to measure temperature, impacts, penetration or leakage of water through the membrane, or a combination thereof.

29. A roofing system, comprising: a roof deck; a plurality of first insulation panels positioned above the roof deck, each of the first insulation panels comprising a first insulation material; a plurality of second insulation panels positioned above the first insulation panels, each of the second insulation panels comprising: a substrate comprising a second insulation material; and a reinforcing sublayer laminated to, attached to, extruded with or molded with the substrate so as to be integrated with the substrate; wherein the reinforcing sublayer defines an upper surface of the second insulation panel and comprising a fiber reinforced polymer composite; and a membrane attached to the reinforcing sublayer and configured to withstand exposure to weather; wherein the membrane comprises at least one of a thermoplastic polyolefin, an ethylene propylene diene monomer, polyvinylchloride, or a modified bitumen material including a base comprising a bituminous asphalt material and a cap sheet attached to the base sheet and comprising a polymeric material; wherein the roofing system does not include an additional layer of coverboards positioned between the roof deck and the membrane.

30. The roofing system of claim 27, wherein the second insulation panels are configured to provide a resistance to cracking upon impact of an object thereagainst such that the roofing system exceeds requirements for Very Severe Hail Resistance according to FM 4473 VSH Impact Resistance Testing Standard for Impact Resistance Testing Standard for Impact Resistance Testing of Rigid Roofing Materials by Impacting with Freezer Ice Balls.

31. The roofing system of claim 27, further comprising a layer of a vapor retardant material positioned between the roof deck and the first insulation panels.

32. The roofing system of claim 27, further comprising an additional reinforcing sublayer attached to a lower surface of the substrate; wherein the additional reinforcing sublayer comprises a fiber reinforced material that is different from the fiber reinforced polymer composite material positioned along the upper surface of the substrate.

33. The roofing system of claim 27, wherein the substrate of the second insulation material comprises polyisocyanurate, mineral wool, expanded polystyrene foam, extruded polystyrene foam, or a combination thereof.

34. A package comprising: plurality of insulation panels including reinforced insulation panels; wherein each of the reinforced insulation panels comprises: a substrate comprising an insulation material; a reinforcing sublayer laminated to, attached to, extruded with or molded with the substrate so as to be integrated with the substrate, the reinforcing sublayer comprising a fiber reinforced polymer composite material; and a membrane comprising at least one of a thermoplastic polyolefin, an ethylene propylene diene monomer, polyvinyl chloride, or a modified bitumen material including a base sheet comprising a bituminous asphalt material and a cap sheet attached to the base sheet and comprising a polymeric material; wherein the reinforced insulation panels are configured to provide a resistance to cracking upon impact of an object thereagainst such that when the reinforced insulation panels are included as part of a roofing system without a coverboard, the roofing system exceeds requirements for Very Severe Hail Resistance according to FM 4473 VSH Impact Resistance Testing Standard for Impact Resistance Testing Standard for Impact Resistance Testing of Rigid Roofing Materials by Impacting with Freezer Ice Balls.

35. The package of claim 34, wherein the reinforced insulation panels further comprise an additional reinforcing sublayer attached to a lower surface of the substrate; wherein the additional reinforcing sublayer comprises a fiber reinforced material that is different from the fiber reinforced polymer composite material positioned along an upper surface of the substrate.

36. The package of claim 34, wherein the reinforced insulation panels each further comprise a membrane attached to an upper surface thereof; wherein the membrane comprises a two-ply modified bitumen material including base sheet attached to the fiber reinforced polymer composite material and comprising a bituminous asphalt material, and a cap sheet applied over the base sheet and comprising a weather resistant polymeric material.

37. The package of claim 34, wherein the reinforced insulation panels each comprise a thickness of 2 inches to 3.75 inches.

38. The package of claim 34, wherein the substrate comprises polyisocyanurate, mineral wool, expanded polystyrene foam, extruded polystyrene foam, or a combination thereof.

39. The package of claim 34, wherein the fiber reinforced polymer composite material comprises a plurality of glass fibers. fiberglass fibers, carbon fibers, natural fibers, or a combination thereof, and a resin material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0097] The accompanying drawings, which are included to provide a further understanding of the embodiments of the present disclosure, are incorporated in and constitute a part of this specification, illustrate embodiments of this disclosure, and together with the detailed description, serve to explain the principles of the embodiments discussed herein. No attempt is made to show structural details of this disclosure in more detail than may be necessary for a fundamental understanding of the exemplary embodiments discussed herein and the various ways in which they may be practiced.

[0098] FIG. 1A is an end view of an example embodiment of a roofing system including a reinforced insulation material layer without a coverboard according to the principles of the present disclosure.

[0099] FIG. 1B is a perspective view of example embodiment of a roofing system including a reinforced insulation material layer without a coverboard according to the principles of the present disclosure.

[0100] FIG. 2A and FIG. 2B show additional embodiments of roofing systems according to the principles of the present disclosure.

[0101] FIG. 3A and FIG. 3B are perspective views illustrating example embodiments of a reinforced insulation material according to the principles of the present disclosure.

[0102] FIG. 4A and FIG. 4B are perspective views illustrating additional example embodiments of a reinforced insulation material according to the principles of the present disclosure.

[0103] FIG. 5A and FIG. 5B are perspective views illustrating further example embodiments of a reinforced insulation material according to the principles of the present disclosure.

[0104] FIG. 6 is a perspective view illustrating still another embodiment of a roofing system including a reinforced insulation material layer and a modified bitumen sheet applied thereover according to the principles of the present disclosure.

[0105] FIG. 7A illustrates an example of a roofing system including a roof deck, a plurality of insulation panels and reinforced insulation panels, and a membrane which roofing system is configured to meet the requirements for Very Severe Hail Resistance according to FM 4473 VSH Impact Resistance Testing Standard for Impact Resistance Testing of Rigid Roofing Materials by Impacting with Freezer Ice Balls, without a coverboard, according to embodiments of the present disclosure.

[0106] FIG. 7B illustrates an example of a roofing system including a roof deck, a plurality of insulation panels and reinforced insulation panels, and a membrane, in which the roofing system is configured to meet the requirements for Very Severe Hail Resistance according to FM 4473 VSH Impact Resistance Testing Standard for Impact Resistance Testing of Rigid Roofing Materials by Impacting with Freezer Ice Balls, without a coverboard, according to embodiments of the present disclosure.

[0107] FIG. 8 illustrates results of comparison testing between an example embodiment of a roofing system incorporating a reinforced insulation material and without a coverboard according to the present disclosure, a roofing system including a conventional coverboard, and a roofing system including a layer of a high density foam insulation, after the roofing systems were subjected to testing in accordance with the FM 4473 VSH Impact Resistance Testing Standard for Impact Resistance Testing of Rigid Roofing Materials by Impacting with Freezer Ice Balls.

[0108] FIG. 9 illustrates results of comparison testing between a modified bitumen roofing system including a coverboard and a modified bitumen roofing system constructed without a coverboard and utilizing a reinforced insulation material according to the principles of the present disclosure, after the roofing systems were subjected to testing in accordance with the FM 4473 VSH Impact Resistance Testing Standard for Impact Resistance Testing of Rigid Roofing Materials by Impacting with Freezer Ice Balls.

DETAILED DESCRIPTION

[0109] Embodiments of the present disclosure will now be described in more detail with reference to the attached drawing figures.

[0110] The present disclosure is directed to roofing systems, methods of installing roofing systems, and to reinforced insulation panels for use in roofing systems as described herein and illustrated in FIGS. 1A-9. In embodiments, the reinforced insulation panels are configured to withstand damage from impacts by hail or other objects thereagainst to protect the roofing systems from exposure to impacts such as from hail, and in particular, very severe hail, without the inclusion of a coverboard in the roofing systems.

[0111] For a roofing system to achieve certification or classification as a hail resistant roofing system, including to be achieve a Very Severe Hail (VSH) certification or classification (Class 4the most stringent certification), the roofing system and components thereof generally must meet the requirements provided under Factory Mutual (FM) hail-resistant test method ANSI FM 4473 Specification test standard for Impact Resistance Testing of Rigid Roofing Materials by Impacting with Freezer Ice Balls (FM 4473). The FM 4473 testing standard for Very Severe Hail Resistance requires the roofing system withstand up to 2-inch ice balls propelled at 152-160 feet per second, resulting in an impact energy of 53-58 ft. lbs. Withstanding such testing may mean, after impact, the roofing system components will not exhibit cracks, dents, and/or other visible damage.

[0112] In addition, in embodiments, other standards and tests may be utilized to classify hail resistant roofing systems and/or components of such roofing systems, such as ASTM D3746 and/or UL 2218. For example, in some embodiments, other testing methods and standards, such as ANSI FM 4470 directed to testing of hail resistance for Single-Ply, Polymer-Modified Bitumen Sheet, Built-Up Roof (BUR) and Liquid Applied Roof Assemblies for use in Class 1 and Noncombustible Roof Deck Construction (FM 4470) can be used.

[0113] The roofing systems 100 (FIGS. 1A-1B) illustrated by the example embodiments of the present disclosure are configured to meet or exceed the FM 4473 testing Standard for Very Severe Hail certification without requiring the use of a coverboard. As used herein, the term coverboard refers to a rigid substrate or board positioned between the upper layer of insulation and a covering membrane applied over the coverboard, and which can be formed from materials such gypsum, including gypsum boards or fiber reinforced gypsum boards, which further can include fiberglass facer, boards made from wood fiber, perlite, mineral fibers, plywood or oriented strand board (OSB), cement and/or other rigid, high density materials. Such coverboards typically range in thickness from about 2 inches to 0.5 inches, and are added to a conventional roofing system to provide strength and rigidity for protection of the roofing system from hail and other objects striking the roof structure. Such coverboards can be expensive and time consuming to install, adding to the complexity and cost of a roofing system.

[0114] In embodiments, roofing systems formed according to the principles of the present disclosure can be used for commercial and residential construction. For example, in embodiments, the roofing systems can be configured to form a low slope roof, including a roof having a slope or pitch of Y/X, where Y corresponds to the rise of the roof, and where X corresponds to the run of the roof. In embodiments, the roof can have a pitch or slope where Y and X are in a ratio of less 4:12. In some embodiments, Y and X are in a ratio of less than 3:12. In some embodiments, Y and X are in a ratio of less than 2:12. In some embodiments, Y and X are in a ratio of less than 1:12. In some embodiments, Y and X are in a ratio of 1:12 to 3:12.

[0115] In other embodiments, the roofing system can be configured to form a roof having a slope of greater than a ratio of 4:12. For example, the roof can have a pitch or slope where Y and X are in a ratio of 4:12 to 12:12. In some embodiments, Y and X are in a ratio of 5:12 to 12:12. In some embodiments, Y and X are in a ratio of 6:12 to 12:12. In some embodiments, Y and X are in a ratio of 7:12 to 12:12. In some embodiments, Y and X are in a ratio of 8:12 to 12:12. In some embodiments, Y and X are in a ratio of 9:12 to 12:12. In some embodiments, Y and X are in a ratio of 10:12 to 12:12. In some embodiments, Y and X are in a ratio of 11:12 to 12:12.

[0116] FIGS. 1A-2B and 6-7B illustrate embodiments of a roof system 100 and components thereof in accordance with the principles of the present disclosure. In embodiments, the roofing system 100 can include a roof deck 101, a first layer 102 positioned above the roof deck 101, a second layer 103 positioned above the first layer 102, and a membrane 104 positioned above an upper surface 105 of the second layer 103. As indicated in FIGS. 2A-2B and 6, in embodiments, the first and second layers 102 and 103 can comprise insulation materials, and can be formed as sheets or panels, as shown in FIGS. 7A-7B, which can, in some embodiments, be stacked on top of each other and over the roof deck during installation of the roofing system 100; or, in other embodiments, rolled out or otherwise applied over an upper surface of the roof deck 101. The roofing system 100 further is configured to be installed without a coverboard.

[0117] In embodiments, the roof deck 101 can comprise a plurality of rafters or beams (e.g., as indicated at 106 in FIGS. 1A-1B); and in embodiments such as indicated in FIGS. 7A-7B, further can include a substrate or decking layer positioned on top of the roof beams or rafters. For example, in embodiments, a substrate or decking comprising metal, wood, concrete or other material panels, or combinations thereof, can be configured to support the other roofing system components, such as the first and second layers 102/103 and the membrane 104 thereover. In some embodiments, as shown in FIG. 1B, the first and second layers can be attached to the rafters or beams 106, or, in some embodiments such as shown in FIGS. 7A-7B, to a further supporting substrate 106A such as metal, wood, concrete or other material panels, by fasteners 112 (FIG. 1B). The fasteners 112 can be inserted through the first and second layers and penetrate into the roof deck, e.g., the beams or decking panels, to secure the first and second layers to the roof deck, after which the membrane 104 can be applied to the upper surface of the second layer, such as by adhesive materials being applied between the membrane and the upper surface of the second layer, or by heat welding, e.g., by torch applied heat.

[0118] In addition, in some embodiments such as indicated in FIG. 1A, a vapor barrier 107, can be positioned between the roof deck 101 and a lower surface of the first layer 102. In embodiments, the vapor barrier 107 can comprise a polymer membrane configured to inhibit passage of moisture into and through the roofing system from the interior of a building on which the roofing system 100 is installed.

[0119] In embodiments, the first layer 102 of the roofing system 100 can comprise a panel or sheet formed from a first insulation material. For example, in embodiments, the first insulation material can comprise polyisocyanurate, mineral wool, polyurethane, expanded polystyrene foam, extruded polystyrene foam, insulation materials including recycled materials, natural fibers, (such as wood or other fibers), or combinations thereof. In embodiments of a method for forming the roofing system, installation of the roofing system 100, as indicated in FIGS. 7A-7B, the first layer 102 can comprise a plurality of panels formed from the first insulation material, which are arranged in an array along the upper surface of the roof deck 101; or, in some embodiments, on top of a vapor barrier 107, as indicated in FIG. 1A.

[0120] In some embodiments, the first layer 102 can be provided with an expanded thickness configured to provide increased resistance to conductive heating therethrough. For example, a roofing system that includes a inch to inch coverboard for impact resistance and insulation properties, can have a resistance to conductive heat flow through the roofing system having an R-value of about R30. In embodiments, the roofing system 100 including the first and second layers 102 and 103 of insulation materials will be configured to provide a resistance to conductive heat flow through the roofing system having an R-value of at least R30, but with the thickness of the overall roofing system substantially matching the thickness of a roofing system having a coverboard positioned between the insulation and a membrane 104.

[0121] In embodiments, the first layer 102 can have a thickness of 1 inch to 2.6 inches; and, in embodiments, can have a thickness of 1 inch to 3.75 inches. In other embodiments, the first layer 102 can have a thickness of 1 inch to 3.65 inches, 1 inch to 3.6 inches, 1 inch to 3.5 inches, 1 inch to 3.4 inches, 1 inch to 3.3 inches, 1 inch to 3.2 inches, 1 inch to 3.1 inches, 1 inch to 3 inches, 1 inch to 2.9 inches, 1 inch to 2.8 inches. 1 inch to 2.7 inches, 1 inch to 2.6 inches, 1 inch to 2.5 inches, 1 inch to 2.4 inches, 1 inch to 2.3 inches, 1 inch to 2.2 inches, 1 inch to 2.1 inches, 1 inch to 2 inches, 1 inch to 1.9 inches, 1 inch to 1.8 inches, 1 inch to 1.7 inches, 1 inch to 1.6 inches, 1 inch to 1.5 inches, 1 inch to 1.4 inches, 1 inch to 1.3 inches, 1 inch to 1.2 inches, 1 inch to 1.1 inches.

[0122] In other embodiments, the first layer 102 can have a thickness of 1.5 inches to 3.75 inches, 1.5 inches to 3.65 inches, 1.5 inches to 3.6 inches, 1.5 inches to 3.5 inches, 1.5 inches to 3.4 inches, 1.5 inches to 3.3 inches, 1.5 inches to 3.2 inches, 1.5 inches to 3.1 inches, 1.5 inches to 3 inches, 1.5 inches to 2.9 inches, 1.5 inches to 2.8 inches, 1.5 inches to 2.7 inches, 1.5 inches to 2.6 inches, 1.5 inches to 2.5 inches, 1.5 inches to 2.4 inches, 1.5 inches to 2.3 inches, 1.5 inches to 2.2 inches, 1.5 inches to 2.1 inches, 1.5 inches to 2 inches, 1.5 inches to 1.9 inches, 1.5 inches to 1.8 inches, 1.5 inches to 1.7 inches, 1.5 inches to 1.6 inches. In other embodiments, the first layer can have a thickness of 2 inches to 3.75 inches, 2 inches to 3.65 inches, 2 inches to 3.6 inches, 2 inches to 3.5 inches, 2 inches to 3.4 inches, 2 inches to 3.3 inches, 2 inches to 3.2 inches, 2 inches to 3.1 inches, 2 inches to 3 inches, 2 inches to 2.9 inches, 2 inches to 2.8 inches, 2 inches to 2.7 inches, 2 inches to 2.6 inches, 2 inches to 2.5 inches, 2 inches to 2.4 inches, 2 inches to 2.3 inches, 2 inches to 2.2 inches, 2 inches to 2.1 inches.

[0123] In some embodiments, the first layer 102 can have a thickness of 2.5 inches to 3.75 inches, 2.5 inches to 3.65 inches, 2.5 inches to 3.6 inches, 2.5 inches to 3.5 inches, 2.5 inches to 3.4 inches, 2.5 inches to 3.3 inches, 2.5 inches to 3.2 inches, 2.5 inches to 3.1 inches, 2.5 inches to 3 inches, 2.5 inches to 2.9 inches, 2.5 inches to 2.8 inches, 2.5 inches to 2.7 inches, 2.5 inches to 2.6 inches. In addition, in embodiments, the first layer can have a thickness of 3 inches to 3.75 inches, 3 inches to 3.65 inches, 3 inches to 3.6 inches, 3 inches to 3.5 inches, 3 inches to 3.4 inches, 3 inches to 3.3 inches, 3 inches to 3.2 inches, or 3 inches to 3.1 inches. Other thicknesses also can be provided.

[0124] In other embodiments, the roofing system 100 can include an additional or third layer of an insulation material, such as indicated at 108 in FIG. 2B, applied to an upper surface 129 of the first layer to increase the thickness of insulation material of the first layer 102. For example, in embodiments, the first layer can have a thickness of 1 inch to 2.6 inches and the third layer 108, which can be formed from a similar insulation material as the first layer, can have a thickness of 0.1 inches to 1.0 inches to increase the thickness of the insulation material of the first layer by an additional, selected amount sufficient to help increase the resistance to conductive heat flow through the roofing system 100 to a value of at least R30, without substantially increasing the thickness of the roofing system as compared to a roofing system including a coverboard.

[0125] By way of example, in embodiments, the first layer 102 can have a thickness of, for example, 1 inch to 3.25 inches and an additional or third layer 108 of an insulation materials can be applied thereover, with the additional or third layer 108 having a thickness of about 0.5 inches so as to increase the total thickness of the insulation material provided by the first layer to 3-3.75 inches. In other embodiments, the additional or third layer 108 can have a thickness of 0.1 to 1 inches, 0.1 to 0.9 inches, 0.1 to 0.8 inches, 0.1 to 0.7 inches, 0.1 to 0.6 inches, 0.1 to 0.5 inches, 0.1 to 0.4 inches, 0.1 to 0.3 inches, 0.1 to 0.2 inches, 0.2 inch to 1 inch, 0.2 inch to 0.9 inch, 0.2 inch to 0.8 inch, 0.2 inch to 0.7 inch, 0.2 inch to 0.6 inch, 0.2 inch to 0.5 inch, 0.2 to 0.4 inch, 0.2 inch to 0.3 inch, 0.3 to 1 inch, 0.3 inch to 0.9 inch, 0.3 inch to 0.8 inch, 0.3 inch to 0.7 inch, 0.3 inch to 0.6 inch, 0.3 inch to 0.5 inch, 0.3 inch to 0.4 inch. Other thicknesses of such an additional or third layer also can be provided.

[0126] In addition, in some embodiments, the third layer 108 can be integrated with the first layer, such as being formed with or laminated to the first layer during manufacture of the first layer. In other embodiments, the third layer 108 can be separately adhered to the first layer 102, such as with an adhesive materials, e.g., during manufacture of the first layer, or in the field as part of the installation of the roofing system 100.

[0127] As further illustrated in FIGS. 1A-3B, in embodiments, the roofing system 100 includes a membrane 104 configured to cover the first and second layers 102/103 of insulation materials and the roof deck 101. In embodiments, the membrane 104 can be configured to seal the roofing system 100 so as to provide water proofing and/or water shedding properties (e.g., being configured to prevent the migration of water therethrough, and/or configure to direct water away from roof deck) to the roofing system 100. In addition, the membrane 104 also can be configured to provide other, additional properties to the roof structure such as UV resistance, additional impact resistance, fire retardant properties, and other properties.

[0128] In embodiments, the membrane 104 can comprise a thermoplastic polyolefin (TPO), an ethylene propylene diene monomer (EPDM), or a polyvinyl chloride (PVC) membrane including a single ply sheet material having a thickness of 20 mils to 120 mils and in some embodiments, a thickness of 20 mils to 110 mils, 20 mils to 100 mils, 20 mils to 90 mils, 20 mils to 80 mils, 20 mils to 70 mils, 20 mils to 60 mils, 20 mils to 50 mils, 20 mils to 40 mils, 20 mils to 30 mils, 30 mils to 120 mils, 30 mils to 110 mils, 30 mils to 100 mils, 30 mils to 90 mils, 30 mils to 80 mils, 30 mils to 70 mils, 30 mils to 60 mils, 30 mils to 50 mils, 30 mils to 40 mils, 40 mils to 120 mils, 40 mils to 110 mils, 40 mils to 100 mils, 40 mils to 90 mils, 40 mils to 80 mils, 40 mils to 70 mils, 40 mils to 60 mils, 40 mils to 50 mils, 50 mils to 120 mils, 50 mils to 110 mils, 50 mils to 100 mils, 50 mils to 90 mils, 50 mils to 80 mils, 50 mils to 70 mils, 50 mils to 60 mils, 60 mils to 120 mils, 60 mils to 110 mils, 60 mils to 100 mils, 60 mils to 90 mils, 60 mils to 80 mils, 60 mils to 70 mils, 70 mils to 120 mils, 70 mils to 110 mils, 70 mils to 100 mils, 70 mils to 90 mils, 70 mils to 80 mils, 80 mils to 120 mils, 80 mils to 110 mils, 80 mils to 100 mils, 80 mils to 90 mils, 90 mils to 120 mils, 90 mils to 110 mils, 90 mils to 100 mils, 100 mils to 120 mils 100 mils to 110 mils, or 110 mils to 120 mils. Other thicknesses of the membrane also can be used.

[0129] In addition, in embodiments, the membrane 104 can comprise a fleece backed TPO membrane, or a TPO membrane with a TPO or PVC adhesive attached EPDM silicone layer or other cushioning material configured to help absorb impacts from hail or other objects striking the upper surface of the membrane. In embodiments, the membrane 104 will define an upper, exposed surface 110 of the roofing system 100, configured to withstand exposure to weather (e.g., withstand exposure to sun, wind, rain, snow, extreme temperatures, extreme cold). In some embodiments, the upper surface of the membrane can be further coated with, for example, an asphalt material, and a covering material such as a plurality of granules applied thereto.

[0130] In still other embodiments, the membrane 104 can comprise a modified bitumen material. As indicated in FIG. 1B, in embodiments, a multi-ply modified bitumen material sheet 115 (e.g., a two ply sheet as shown in FIG. 1B) can be applied along the upper surface of the second layer; and in embodiments, can include a base sheet 116 and a cap sheet 117. In embodiments, the base sheet 116 can comprise a bituminous asphalt material, while the cap sheet 117 can comprise a polymeric material. For example, in embodiments, the cap sheet can comprise a TPO, EPDM, or PVC membrane, that is weather resistant.

[0131] In addition, in embodiments, a layer of granules can be applied over the membrane 104. For example, in embodiments, the upper surface of the cap sheet 117 can be coated with an asphalt material, and a plurality of granules applied over the cap sheet and being adhered thereto by the asphalt. The granules can be selected and applied to help increase reflectivity of sunlight. In other embodiments, granules may not be applied.

[0132] In some embodiments, the base sheet and the cap sheet can be attached or bonded together, such as by an adhesive, heat welding, or a combination thereof, or otherwise formed together as an integrated modified bitumen material sheet 115 to form the membrane 104. In still other embodiments, a single layer of a bituminous asphalt material (e.g., the base layer 116) that can be applied directly to the upper surface of the second layer 103, with the cap sheet 117 thereafter positioned over the layer of bituminous asphalt material, and attached thereto. In embodiments, the modified bitumen material sheet 115 can be applied over the upper surface of the second layer, and can be attached thereto by application of an adhesive material, which can include a hot adhesive such as a heated asphalt adhesive material, cold adhesives, or by heat welding, such as, for example, by use of a torch to apply heat to the modified bitumen material sheet 115.

[0133] For example, in embodiments, the base sheet can comprise a fibrous mat including a plurality of fibers such as glass or fiberglass fibers, carbon fibers, or other reinforcing fibers, impregnated with a polymeric material, e.g., a thermoplastic elastomer such as, styrene-butadiene-styrene. In embodiments, the cap sheet can comprise a mat formed from glass or fiberglass fibers and coated with asphalt. In some embodiments, other materials, including sheets formed from polymeric materials also can be used. In embodiments, the cap sheet further can include a face surfacing material along an upper surface thereof, e.g., in some embodiments, a plurality of granules can be applied to the upper surface of the cap sheet and adhered thereto by the asphalt coating. In embodiments, the upper surface of the base sheet can be coated with an adhesive, such as asphalt, or, in embodiments, a cold adhesive material, so as to adhere the base sheet to the cap sheet. In addition, in embodiments, a parting agent, such as silica (e.g., sand) can be applied to the upper surface of the base sheet or the lower surface of the cap sheet.

[0134] In embodiments, the modified bitumen material sheet 115 can have a thickness of 20 mils to 120 mils and in some embodiments, a thickness of 20 mils to 110 mils, 20 mils to 100 mils, 20 mils to 90 mils, 20 mils to 80 mils, 20 mils to 70 mils, 20 mils to 60 mils, 20 mils to 50 mils, 20 mils to 40 mils, 20 mils to 30 mils, 30 mils to 120 mils, 30 mils to 110 mils, 30 mils to 100 mils, 30 mils to 90 mils, 30 mils to 80 mils, 30 mils to 70 mils, 30 mils to 60 mils, 30 mils to 50 mils, 30 mils to 40 mils, 40 mils to 120 mils, 40 mils to 110 mils, 40 mils to 100 mils, 40 mils to 90 mils, 40 mils to 80 mils, 40 mils to 70 mils, 40 mils to 60 mils, 40 mils to 50 mils, 50 mils to 120 mils, 50 mils to 110 mils, 50 mils to 100 mils, 50 mils to 90 mils, 50 mils to 80 mils, 50 mils to 70 mils, 50 mils to 60 mils, 60 mils to 120 mils, 60 mils to 110 mils, 60 mils to 100 mils, 60 mils to 90 mils, 60 mils to 80 mils, 60 mils to 70 mils, 70 mils to 120 mils, 70 mils to 110 mils, 70 mils to 100 mils, 70 mils to 90 mils, 70 mils to 80 mils, 80 mils to 120 mils, 80 mils to 110 mils, 80 mils to 100 mils, 80 mils to 90 mils, 90 mils to 120 mils, 90 mils to 110 mils, 90 mils to 100 mils, 100 mils to 120 mils 100 mils to 110 mils, or 110 mils to 120 mils. Other thicknesses also could be used.

[0135] In embodiments, the second layer 103 can comprise a reinforced insulation material 120 formed according to the principles of the present disclosure; and in some embodiments, can comprise a pre-fabricated structural insulation component of the roofing system 100. In embodiments, the second layer can comprise sheets or panels that can be stacked over sheets of panels of the first layer 102, which includes the first insulation material, as shown in FIGS. 2A-5B.

[0136] In embodiments, the second layer 103 can have a thickness of 1 inch to 2.6 inches; and, in some embodiments, can have a thickness of 1 inch to 3.65 inches, 1 inch to 3.5 inches 1 inch to 3.4 inches, 1 inch to 3.3 inches, 1 inch to 3.2 inches, 1 inch to 3.1 inches, 1 inch to 3 inches, 1 inch to 2.9 inches, 1 inch to 2.8 inches. 1 inch to 2.7 inches, 1 inch to 2.6 inches, 1 inch to 2.5 inches, 1 inch to 2.4 inches, 1 inch to 2.3 inches, 1 inch to 2.2 inches, 1 inch to 2.1 inches, 1 inch to 2 inches, 1 inch to 1.9 inches, 1 inch to 1.8 inches, 1 inch to 1.7 inches, 1 inch to 1.6 inches, 1 inch to 1.5 inches, 1 inch to 1.4 inches, 1 inch to 1.3 inches, 1 inch to 1.2 inches, 1 inch to 1.1 inches.

[0137] In other embodiments, the second layer 103 can have a thickness of 1.5 inches to 3.65 inches, 1.5 inches to 3.6 inches, 1.5 inches to 3.5 inches, 1.5 inches to 3.4 inches, 1.5 inches to 3.3 inches, 1.5 inches to 3.2 inches, 1.5 inches to 3.1 inches, 1.5 inches to 3 inches, 1.5 inches to 2.9 inches, 1.5 inches to 2.8 inches, 1.5 inches to 2.7 inches, 1.5 inches to 2.6 inches, 1.5 inches to 2.5 inches, 1.5 inches to 2.4 inches, 1.5 inches to 2.3 inches, 1.5 inches to 2.2 inches, 1.5 inches to 2.1 inches, 1.5 inches to 2 inches, 1.5 inches to 1.9 inches, 1.5 inches to 1.8 inches, 1.5 inches to 1.7 inches, 1.5 inches to 1.6 inches.

[0138] In other embodiments, the second layer 103 can have a thickness of 2 inches to 3.65 inches, 2 inches to 3.6 inches, 2 inches to 3.5 inches, 2 inches to 3.4 inches, 2 inches to 3.3 inches, 2 inches to 3.2 inches, 2 inches to 3.1 inches, 2 inches to 3 inches, 2 inches to 2.9 inches, 2 inches to 2.8 inches, 2 inches to 2.7 inches, 2 inches to 2.6 inches, 2 inches to 2.5 inches, 2 inches to 2.4 inches, 2 inches to 2.3 inches, 2 inches to 2.2 inches, 2 inches to 2.1 inches. In some embodiments, the first layer can have a thickness of 2.5 inches to 3.6 inches, 2.5 inches to 3.5 inches, 2.5 inches to 3.4 inches, 2.5 inches to 3.3 inches, 2.5 inches to 3.2 inches, 2.5 inches to 3.1 inches, 2.5 inches to 3 inches, 2.5 inches to 2.9 inches, 2.5 inches to 2.8 inches, 2.5 inches to 2.7 inches, 2.5 inches to 2.6 inches. In addition, in embodiments, the first layer can have a thickness of 3 inches to 3.65 inches, 3 inches to 3.6 inches, 3 inches to 3.5 inches, 3 inches to 3.4 inches, 3 inches to 3.3 inches, 3 inches to 3.2 inches, or 3 inches to 3.1 inches. Other thicknesses also can be provided.

[0139] In embodiments, as shown in FIGS. 1A-1B, the reinforced insulation material 120 of the second layer 103 can include a substrate 121 having a first or upper surface 122 and a second or bottom surface 123. The substrate 121 will be formed from a second insulation material that, in embodiments, can comprise polyisocyanurate, polyurethane, mineral wool, expanded polystyrene foam, extended polystyrene foam, or combinations thereof. In embodiments, the second insulation material of the substrate 121 can be formed from the same material as the first insulation material of the first layer 102.

[0140] In embodiments, the substrate 121 can have a thickness of 1 inch to 3.0 inches. In other embodiments, the substrate 121 can have a thickness of 1 inch to 2.9 inches, 1 inch to 2.8 inches. 1 inch to 2.7 inches, 1 inch to 2.6 inches, 1 inch to 2.5 inches, 1 inch to 2.4 inches, 1 inch to 2.3 inches, 1 inch to 2.2 inches, 1 inch to 2.1 inches, 1 inch to 2 inches, 1 inch to 1.9 inches, 1 inch to 1.8 inches, 1 inch to 1.7 inches, 1 inch to 1.6 inches, 1 inch to 1.5 inches, 1 inch to 1.4 inches, 1 inch to 1.3 inches, 1 inch to 1.2 inches. In other embodiments, the second layer 103 can have a thickness of 1.5 inches to 3 inches, 1.5 inches to 2.9 inches, 1.5 inches to 2.8 inches, 1.5 inches to 2.7 inches, 1.5 inches to 2.6 inches, 1.5 inches to 2.5 inches, 1.5 inches to 2.4 inches, 1.5 inches to 2.3 inches, 1.5 inches to 2.2 inches, 1.5 inches to 2.1 inches, 1.5 inches to 2 inches, 1.5 inches to 1.9 inches, 1.5 inches to 1.8 inches, 1.5 inches to 1.7 inches, 1.5 inches to 1.6 inches. In other embodiments, the second layer 103 can have a thickness of 2 inches to 3 inches, 2 inches to 2.9 inches, 2 inches to 2.8 inches, 2 inches to 2.7 inches, 2 inches to 2.6 inches, 2 inches to 2.5 inches, 2 inches to 2.4 inches, 2 inches to 2.3 inches, 2 inches to 2.2 inches, 2 inches to 2.1 inches. In some embodiments, the second layer can have a thickness of 2.5 inches to 3 inches, 2.5 inches to 2.9 inches, 2.5 inches to 2.8 inches, 2.5 inches to 2.7 inches, 2.5 inches to 2.6 inches

[0141] In embodiments, such as illustrated in FIGS. 1A-5B, the reinforced insulation material 120 of the second layer 103 further can include a reinforcing sublayer 125 applied to the first or upper surface 122 of the substrate. In embodiments, the reinforcing sublayer 125 is integrated with the substrate 121. For example, in embodiments, the reinforcing sublayer 125 can be pre-fabricated with the substrate, such as by being attached to the substrate (e.g., by adhesives, thermal bonding or a combination thereof), or being extruded with, molded with, or laminated to the first or upper surface 122 of the substrate.

[0142] In some embodiments, the insulation material substrate 121 of the reinforced insulation material, including a polyisocyanurate, polyurethane, polystyrene, or other insulation material, can be attached to the reinforcing sublayer as part of a direct foaming process of manufacturing the insulation material. In embodiments, the reinforcing sublayer can be formed into a sheet or scrim, such as by mixing a sheet molding compound with chopped reinforcing fibers (e.g., glass, fiberglass, natural fibers, polymer fibers such as polyester, carbon fibers, or other cut or chopped fibers) and forming the mixture into a sheet, or, in some embodiments, a plurality of continuous reinforcing fibers (e.g., glass, fiberglass, natural fibers, polymer fibers such as polyester, carbon fibers, or other cut or chopped fibers) can be mixed with a resin and extruded to form the fiber reinforced polymer composite sheet.

[0143] The fiber reinforced polymer composite sheet then can be moved along a processing path, along which a foam mixture, that, in embodiments, can include a polyisocyanurate and at least one isocyanate reactive compound deposited along the first surface of the fiber reinforced polymer composite sheet. As the polyisocyanurate and at least one isocyanate reactive compound of the foam mixture reacts and expands, the reinforcing sublayer 125 can be encapsulated with or bonded to the insulation substrate so as to thus be substantially integrated with the substrate and can define the upper surface 105 of the second layer 103.

[0144] Alternatively, in some embodiments, the fiber reinforced polymer composite sheet can be formed and moved along a processing path, and a substrate comprising an insulation material, such as polyisocyanurate, polyurethane, mineral wool, expanded polystyrene foam, extended polystyrene foam, or combinations thereof, can be positioned along one side surface of the fiber reinforced polymer composite sheet, and attached thereto to form the reinforced insulation material. For example, in embodiments, an adhesive material can be applied to at least one of the fiber reinforced polymer composite sheet or the substrate, such that as the fiber reinforced polymer composite sheet and the substrate are brought into registration together, they will be adhesively attached to form the reinforced composite insulation material 120. In embodiments, the adhesive material can include isocyanate terminated urethane polymers, methacrylate's, butyl-based adhesives, polymer modified asphaltic materials, polyurethane foams, rubber contact adhesives. Other adhesive materials also can be used.

[0145] After formation, in embodiments, the reinforced insulation material can be formed into rolls, or cut into panels which can be packaged for shipment. For example, packages having one or more rolls of reinforced insulation materials, or a plurality of reinforced insulation material panels 120 stacked together can be formed. In embodiments, such packages can include 5-10 reinforced insulation material panels. In some embodiments, the packages can include 5-9 panels, 5-8 panels, 5-7 panels, 5-6 panels, 6-10 panels, 6-9 panels, 6-8 panels, 6-7 panels, 7-10 panels, 7-9 panels, 7-8 panels, 8-10 panels, 8-9 panels, or 9-10 panels. Other numbers of panels also can be provided. Still further, in other embodiments, the reinforced insulation materials can be formed as other types of roofing materials, for example, shingles, tiles, or other materials, packaged together in stacks.

[0146] In embodiments, the packages can include additional components including a membrane 104 (e.g., a roll or sheets of TPO, EPDM, PVC, or Modified Bitumen) and an adhesive material. Alternatively, in some embodiments, the reinforced insulation panels of the packages can be provided with a membrane pre-fabricated or attached thereto, with or without an additional membrane material being provided as part of the packages. Still further, in some embodiments, a plurality of insulation panels, such as for forming the first layer 102, which do not include a fiber reinforced polymer composite sheet, also can be provided as part of the packages.

[0147] In embodiments, such as shown in FIGS. 1A-1B, and 6, the membrane 104, e.g., a TPO membrane, may be positioned over or attached to the reinforcing sublayer 125. In embodiments, the membrane 104 can be attached with a TPO or PVC adhesive. In some embodiments, such as where the membrane 104 includes a Modified Bitumen material 115 (FIG. 6), the bituminous asphalt of the base layer 116 can adhere the base layer and cap sheet of the Modified Bitumen material 115, with or without an additional adhesive being required.

[0148] In addition, in embodiments, the packages can further include one or more sensors adapted to measure temperature, impacts, penetration or leakage of water through the membrane. Other sensors or smart materials also can be provided. In embodiments, such sensors or smart materials can be applied to a surface of the reinforced insulation material; for example, placed along a surface of the reinforced insulation material (e.g., the upper surface) being inserted into the reinforced insulation material, adhered a surface of the reinforced insulation material, or combinations thereof, by installer in the field. Alternatively, in some embodiments, the packages can include reinforced insulation materials (e.g., a plurality of reinforced insulation panels) having one or more sensors integrated therewith. For example, the packages can include reinforced insulation panels with sensors attached to the second layer 103 during manufacture thereof, e.g., being laminated to the substrate, being embedded within the substrate, attached to the reinforcing sublayer, or combinations thereof, as part of the manufacturing process of the reinforced insulation panels. Still further, the packages can also include insulation panels 102 (without a reinforcing sublayer), which include one or more sensors.

[0149] In embodiments, as shown in FIG. 3B, the reinforcing sublayer 125 can be configured as a fiber reinforced polymer composite material 137 applied to the first or upper surface 122 of the substrate 121 to form a protective barrier layer integrated with the substrate such that the second layer 103 is configured to provide a resistance to cracking upon impact of an object thereagainst such that the roofing system exceeds the requirements of the FM 4473 testing Standard for Very Severe Hail certification. In addition, in embodiments, the fiber reinforced polymer composite material 137 can comprise a water impermeable skin (adapted to inhibit passage of water therethrough); and in some embodiments, the fiber reinforced polymer composite material 137 can provide additional insulative properties to the second layer, such that the roofing system 100 can be provided with a resistance to conductive heat flow through the roofing system having an R-value of greater than R30, without requiring the use of a coverboard for either very severe hail resistance or enhanced insulative properties, and without substantially increasing the overall thickness of the roofing system.

[0150] In embodiments, the fiber reinforced polymer composite material 137 can comprise a sheet formed by molding a plurality of reinforcing fibers 126 with a sheet molding compound. In other embodiments, the fiber reinforced polymer composite material 137 can comprise a sheet formed by a pultrusion process and including a resin and a plurality of substantially continuous reinforcing fibers. For example, in embodiments, the reinforcing fibers 126 can be mixed with a resin 127 comprising a polymer, a biodegradable material, low-carbon footprint material, or a combination thereof.

[0151] In embodiments, the fibers 126 and resin material 127 can be mixed in a selected ratio to form a skin or facer sheet of a selected thickness. By way of example only, in some embodiments, the resin and fibers can be mixed in a ratio of 10% fibers to 90% resin; and in other embodiments, can be mixed in a ratio of 10% fibers to 80% resin, 10% fibers to 70% resin, 10% fibers to 60% resin, 10% fibers to 50% resin, 10% fibers to 40% resin, 10% fibers to 30% resin, 10% fibers to 20% resin, 20% fibers to 90% resin, 20% fibers to 80% resin, 20% fibers to 70% resin, 20% fibers to 60% resin, 20% fibers to 50% resin, 20% fibers to 40% resin, 20% fibers to 30% resin, 30% fibers to 90% resin, 30% fibers to 80% resin, 30% fibers to 70% resin, 30% fibers to 60% resin, 30% fibers to 50% resin, 30% fibers to 40% resin, 40% fibers to 90% resin, 40% fibers to 80% resin, 40% fibers to 70% resin, 40% fibers to 60% resin, 40% fibers to 50% resin, 50% fibers to 90% resin, 50% fibers to 80% resin, 50% fibers to 70% resin, or 50% fibers to 60% resin. Other mixture ratios may also be used.

[0152] In some embodiments, fiber reinforced polymer composite material 137 can be formed as a sheet, and in some alternative embodiments can include a scrim having a plurality of reinforcing fibers 126 and a resin material 127 integrated therewith. The scrim material may comprise a woven material, non-woven material, mesh material, netting or belted materials, or combination thereof. The scrim material may further be comprised of polyester, glass, polyester/glass hybrid, nylon, polypropylene, or some combinations thereof. In addition, in embodiments, the scrim material of the fiber reinforced polymer composite material 137 may comprise various patterns, such as an over/under pattern, tri-directional pattern, quad-directional pattern, or some combination thereof.

[0153] In embodiments, the reinforcing fibers 126 can comprise a plurality of glass fibers, fiberglass fibers, carbon fibers, natural fibers, natural fibers (such as wood fibers and other natural fibers), or a combination thereof. For example, in embodiments, the reinforcing fibers 126 can include substantially continuous or chopped glass or carbon fibers, fiberglass filaments, or other reinforcing fibers that, when combined with appropriate resins, have a selected impact resistance.

[0154] In addition, in embodiments, the fiber reinforced polymer composite material 137 can comprise a thickness of 0.5 millimeter to 8 millimeters; and in some embodiments, a thickness of 0.5 millimeter to 7 millimeters, 0.5 millimeter to 6 millimeters, 0.5 millimeter to 5 millimeters, 0.5 millimeter to 4 millimeters, 0.5 millimeter to 3 millimeters, 0.5 millimeter to 2 millimeters, 0.5 millimeter to 1 millimeter, 1 millimeter to 8 millimeters, 1 millimeter to 7 millimeters, 1 millimeter to 6 millimeters, 1 millimeter to 5 millimeters, 1 millimeter to 4 millimeters, 1 millimeter to 3 millimeters, 1 millimeter to 2 millimeters, 2 millimeters to 8 millimeters, 2 millimeters to 7 millimeters, 2 millimeters to 6 millimeters, 2 millimeters to 5 millimeters, 2 millimeters to 4 millimeters, 2 millimeters to 3 millimeters, 3 millimeters to 8 millimeters, 3 millimeters to 7 millimeters, 3 millimeters to 6 millimeters, 3 millimeters to 5 millimeters, 3 millimeters to 4 millimeters, 4 millimeters to 8 millimeters, 4 millimeters to 7 millimeters, 4 millimeters to 6 millimeters, 4 millimeters to 5 millimeters, 5 millimeters to 8 millimeters, 5 millimeters to 7 millimeters, 5 millimeters to 6 millimeters, 6 millimeters to 8 millimeters, 6 millimeters to 7 millimeters, or 7 millimeters to 8 millimeters. Other thicknesses of the fiber reinforced polymer composite material also can be used.

[0155] Further, in some embodiments, an additional reinforcing sublayer 128 (FIG. 2B) can be applied to the second surface 123 of the substrate 121. In embodiments, the additional reinforcing sublayer 128 can comprise a fiber reinforced skin or reinforced sheet material that is different from the fiber reinforced polymer composite skin positioned along the first or upper surface 122 of the substrate 121. For example, in embodiments, the additional reinforcing sublayer 128 can comprise a facer comprising a mesh, scrim, fabric, paper, of a combination thereof, and which further can include reinforcing materials such as glass fibers.

[0156] FIGS. 3A-5B illustrate additional, non-limiting example embodiments of a reinforcing insulation material 120 for use as the second layer 103 of the insulation in the roofing system 100 according to the principles of the present disclosure.

[0157] In one example embodiment, shown in FIG. 3A, the reinforced insulation material 120 can include a substrate 121 having a first surface 122 and second surface 123. In embodiments, the substrate 121 can comprise a polyisocyanurate insulation material, such as GAF Energy Guard polyiso insulation, from GAF of Parsippany, New Jersey. In embodiments, first reinforcing sublayer 125 can be applied to the first surface 122 of the substrate, defining the upper surface 105 of the second layer 103 and, in some embodiments, an additional, second reinforcing sublayer 128 can be applied to the second surface 123 of the substrate, e.g., as illustrated in FIGS. 3A-3B.

[0158] In embodiments, such as shown in FIG. 3A, the first reinforcing sublayer 125 can comprise a glass-coated facer 135, which, in some embodiments, further can comprise a glass-coated fiberglass facer. In embodiments, the first reinforcing sublayer further can include a mesh or scrim, with a coating mixture of a polymer and a plurality of reinforcing fibers applied thereto. In embodiments, the glass-coated facer 135 can have a thickness of 0.5 millimeter to 2 millimeters, 0.5 millimeter to 1.75 millimeter, 0.5 millimeter to 1.5 millimeter, 5 millimeter to 1 millimeter, 0.5 millimeter to.75 millimeter, 1 millimeter to 2 millimeters, 1 millimeter to 1.75 millimeter, 1 millimeter to 1.5 millimeter, 1.5 millimeter to 2 millimeter, 1.5 millimeter to 1.75 millimeter, 1.75 millimeter to 2 millimeters, or other thicknesses.

[0159] In addition, in embodiments, the second reinforcing layer 128 can comprise a reinforced polymer composite material skin 136 that is applied along the second surface of the substrate opposite the first reinforcing sublayer, as shown in FIGS. 3A-3B. In other embodiments, the first reinforcing sublayer 125 also can comprise a reinforced polymer composite material 137, (FIG. 3B). In embodiments, the first reinforcing sublayer and the second reinforcing layer can comprise a similar reinforced polymer composite material. In some embodiments, the fiber reinforced polymer composite material skin 136 of the second reinforcing sublayer 128 can be formed from a different fiber reinforced polymer composite material than the fiber reinforced polymer composite material skin 137 of the first reinforcing sublayer 125.

[0160] In embodiments, one or both of the first and second reinforcing sublayers 125 and 128 can be formed with the substrate 121. For example, in embodiments, one or both of the first and second reinforcing layers can be formed with the substrate as part of a direct foaming process wherein, during formation of the substrate, the polyisocyanurate insulation material of the substrate is directly formed onto the first and/or second reinforcing sublayers, so as to form the integrated reinforced insulation material 120.

[0161] FIGS. 4A-4B illustrate still another embodiment of a reinforced insulation material 120 that can be used as the second layer 103 of insulation material of the roofing system 100 according to the principles of the present disclosure. As illustrated in FIGS. 4A-4B, the reinforced insulation material 120 can include a substrate 121, which, in embodiments, can be formed from a polyisocyanurate insulation material, such as GAF Energy Guard polyiso insulation from GAF of Parsippany, New Jersey. In embodiments, the substrate 121 can include a first surface 122 and a second surface 123, with a first reinforcing sublayer 125 applied to the first surface 122, defining the upper surface 105 of the second layer 103; and in some embodiments, a second or additional reinforcing sublayer 128 applied to the second surface 123 of the substrate. In embodiments, the first and second reinforcing sublayers can be formed with or otherwise integrated with the substrate during formation of the substrate, such as by a direct foaming process.

[0162] In one example embodiment shown in FIG. 4A, the first reinforcing sublayer 125 can comprise a Kraft-paper facer material, indicated at 138, and the second reinforcing sublayer can comprise a fiber reinforced polymer material skin 136. In other embodiments, such as shown in FIG. 4B, the first reinforcing sublayer 125 can include a fiber reinforced polymer composite material skin 137. In embodiments, the first reinforcing sublayer and the second reinforcing sublayer can comprise a similar fiber reinforced polymer composite material. In other embodiments, the first and second reinforcing sublayers can comprise different fiber reinforced polymer composite materials. In addition, in some embodiments, a facer 138A, e.g., a Kraft-paper facer or other, similar facer, also can be applied to the first surface 122 of the substrate, being positioned between the substrate and the first reinforcing sublayer, as indicated in FIG. 4B.

[0163] FIGS. 5A and 5B illustrate still further embodiments of a reinforced insulation material 120 for use as the second layer 103 of insulation material of the roofing system 100 according to the principles of the present disclosure. As illustrated in FIGS. 5A and 5B, the reinforced insulation material 120 can include a substrate 121 that can be formed from a polyisocyanurate insulation material, such as GAF Energy Guard polyiso insulation from GAF of Parsippany, New Jersey. In embodiments, the substrate 121 will include a first surface 122 and a second surface 123, with a first reinforcing sublayer 125 being applied to the first surface, defining the upper surface 105 of the second layer 103; and, in some embodiments, a second reinforcing sublayer 128 can be applied to the second surface 123 of the substrate. In embodiments, the first and second reinforcing sublayers can be formed with or otherwise integrated with the substrate such as during a direct foaming process for formation of the substrate, wherein the substrate is formed onto the first and/or second reinforcing sublayers.

[0164] In an example embodiment shown in FIG. 5A, the first reinforcing sublayer can comprise a glass fiber mat 139 having a reinforced scrim or mesh material; for example, a fiber reinforced scrim or mesh having a plurality of reinforcing fibers integrated with a mat of glass fibers mixed with a polymer resin material, forming glass fiber reinforced polymer composite material skin applied along the upper surface of the substrate. As illustrated in FIG. 5A, in embodiments, the second reinforcing sublayer 128 can comprise a fiber reinforced polymer composite material skin 136. As illustrated in FIG. 5B, in embodiments, the first reinforcing sublayer 125 and the second reinforcing sublayer 128 can each comprise a fiber reinforced polymer composite material 137. In embodiments, the first reinforcing sublayer and the second reinforcing sublayer can comprise a similar fiber reinforced polymer composite material. In other embodiments, the first and second reinforcing sublayers can comprise different fiber reinforced polymer composite materials.

[0165] As further illustrated in FIGS. 4B and 5B, in some embodiments, an additional sublayer 140 can be positioned between the first surface 122 of the substrate and the first reinforcing sublayer 125; and, in some embodiments, can comprise a third reinforcing sublayer. In some embodiments, such as shown in FIG. 5B, another sublayer 141 can be positioned between the second surface 123 of the substrate 121 and the second reinforcing sublayer 128; and, in some embodiments, can comprise a fourth reinforcing sublayer. In embodiments, the sublayers 140 and 141 can each comprise a fiber reinforced mat material. For example, in embodiments, the additional sublayers 140 and 141 can comprise a glass fiber mat supported by a reinforced scrim or mesh material, e.g., a scrim or mesh including a plurality of reinforcing fibers mixed with a polymer resin material, for example, including a latex material. In other embodiments, the additional sublayers 140 and 141 can comprise different materials, e.g., a facer such as a kraft-paper facer as indicated in FIG. 4B, a glass-coated facer, as well as other reinforcing materials and materials configured to provide additional protection against passage of water, insulation properties, and other properties.

[0166] In embodiments, the fiber reinforced polymer composite material skins 137 and 136 of the first and second reinforcing sublayers 125 and 128 shown in the embodiments of FIGS. 3B and 4B can each comprise a thickness of 1 millimeter to 8 millimeters, in some embodiments, a thickness of 1 millimeter to 7 millimeters, 1 millimeter to 6 millimeters, 1 millimeter to 5 millimeters, 1 millimeter to 4 millimeters, 1 millimeter to 3 millimeters, 1 millimeter to 2 millimeters, 2 millimeters to 8 millimeters, 2 millimeters to 7 millimeters, 2 millimeters to 6 millimeters, 2 millimeters to 5 millimeters, 2 millimeters to 4 millimeters, 2 millimeters to 3 millimeters, 3 millimeters to 8 millimeters, 3 millimeters to 7 millimeters, 3 millimeters to 6 millimeters, 3 millimeters to 5 millimeters, 3 millimeters to 4 millimeters, 4 millimeters to 8 millimeters, 4 millimeters to 7 millimeters, 4 millimeters to 6 millimeters, 4 millimeters to 5 millimeters, 5 millimeters to 8 millimeters, 5 millimeters to 7 millimeters, 5 millimeters to 6 millimeters, 6 millimeters to 8 millimeters, 6 millimeters to 7 millimeters, or 7 millimeters to 8 millimeters. Other thicknesses of the fiber reinforced polymer composite material skins of the first and second reinforcing sublayers also can be used.

[0167] In addition, in some embodiments, such as indicated in FIGS. 3B, 4B, and 5B, the first reinforcing sublayer 125 can have a thickness that is different from a thickness of the second reinforcing sublayer. In some embodiments, the first reinforcing sublayer can have a thickness that is greater than the thickness of the second reinforcing sublayer.

[0168] For example, as indicated in FIGS. 4B and 5B, in embodiments, the first reinforcing sublayer 125 can have a thickness of 2 millimeters to 8 millimeters; and in some embodiments, can have a thickness of 2 millimeters to 7 millimeters, 2 millimeters to 6 millimeters, 2 millimeters to 5 millimeters, 2 millimeters to 4 millimeters, 2 millimeters to 3 millimeters; while, in embodiments, the second reinforcing sublayer can comprise a thickness of 0.5 millimeter to 3 millimeters, 0.5 millimeter to 2.5 millimeters, 0.5 millimeter to 2 millimeters, 0.5 millimeter to 1.5 millimeters, 0.5 millimeter to 1 millimeter, 1 millimeter to 3 millimeters, 1 millimeter to 2.5 millimeters, 1 millimeter to 2 millimeters, 1 millimeter to 1.5 millimeters, 1.5 millimeters to 3 millimeters, 1.5 millimeters to 2.5 millimeters, 1.5 millimeters to 2 millimeters, 2 millimeters to 3 millimeters, or 2.5 millimeters to 3 millimeters. Other thicknesses also can be used.

[0169] In addition, in some embodiments, one or more smart materials and sensors also can be integrated into the second layer. For example, sensors adapted to measure temperature, impacts, penetration or leakage of water through the membrane, and other sensors can be provided. Such sensors or smart materials can be integrated with the second layer 103 during manufacture thereof, e.g., being embedded into or laminated to the substrate with the reinforcing sublayer, or, in some embodiments, can be applied along a surface, of the reinforcing sublayer (e.g., the upper surface thereof) prior to installation of the membrane in the field. In embodiments, sensors also can be provided as part of a package of roofing materials, which, in some embodiments, could include one or more rolls or panels or roofing materials, e.g., including a plurality of reinforced insulation sheets, panels, shingles, tiles, etc., with sensors integrated therewith.

[0170] In FIGS. 7A-7B, example of a roofing system 100 according to the principles of the present disclosure are illustrated. In an embodiment, a method of installing the roofing system 100 includes a roof deck 101, and the method of installing the roofing system 100 includes positioning a first layer 102 comprising a first insulation material on top of the roof deck. As shown in FIGS. 7A-7B, the roof deck can include a substrate or decking, which, in embodiments, can comprise metal, wood, concrete or other material panels, beams or rafters, or combinations thereof, and which will be configured to support the other roofing system components. In some embodiments, a vapor barrier 107 also can be first applied along the roof deck prior to positioning the first layer 102 therealong. The first layer 102 can be secured over the roof deck 101 by adhesive, mechanical fasteners (e.g., fasteners 112 as shown in FIG. 1B), or other attachments. In addition, as indicated in FIGS. 2A, 3B, 4B and 5B, the first layer 102 can be provided with an additional thickness; while in some embodiments, an additional or third layer of insulation can be attached to the first layer.

[0171] Thereafter, a second layer 103 comprising a second insulation material, e.g., the reinforced insulation material 120, is applied over the first layer 102. In embodiments, a layer of an adhesive material will be applied to an upper surface 129 of the first layer 102 for attaching the first layer 102 to the second layer 103. In embodiments, such as shown in FIG. 1B, the first and second layers 102/103 can be attached to the roof deck by fasteners 112; or, in some embodiments, by an adhesive material. Thereafter, an adhesive material 131 configured to attach the membrane 104 to the reinforcing sublayer 125 of the second layer can be applied along the upper surface of the second layer 103, as indicated in FIG. 1A. For example, in embodiments, the adhesive material can include TPO or PVC adhesives, isocyanate terminated urethane polymers, methacrylate's, butyl-based adhesives, polymer modified asphaltic materials, polyurethane foams, rubber contact adhesives, or combinations thereof

[0172] As shown in FIG. 7A, in embodiments, the first and second layers 102/103 can comprise a plurality of panels arranged in stacked series on top of the roof deck 101. The panels of the first and second layers further can be arranged in an array of rows and columns across and along the roof deck, and, in some embodiments, can be arranged in a staggered or offset arrangement. In some additional embodiments, a further sealing material such as a tape or similar material also can be applied along the seams or joints defined by abutting edges of adjacent panels.

[0173] Alternatively, in embodiments where the reinforced insulation panels each include a TPO, EPDM, PVC, or modified Bitumen membrane pre-attached to the upper surfaces thereof. For example, in embodiments, as illustrated in FIG. 7B, the membrane 109 can be pre-applied to each of the reinforced insulation panels 120 as a sheet 150; and in embodiments, further can include a flange portion 151 that projects from one or more of the peripheral edges of each of the reinforced insulation panels. The flange portions 151 can be configured to overlap an upper surface of one or more adjacent reinforced insulation panels 120, such as overlapping and lying against an upper surface 110 of the membrane 104 of the one or more adjacent reinforced insulation panels. In embodiments, the flanges 151 can be secured to the upper surfaces of the one or more adjacent reinforced insulation panels by adhesives, heat welding, tape, or a combination thereof.

[0174] FIG. 8 illustrates a comparison of roofing systems being subjected to impacts from ice balls striking the surface of each roofing system. The roofing systems compared in FIG. 8 include an example roofing system constructed in accordance with embodiments of the present disclosure (shown in the center column) and including a 60 mil TPO single ply membrane applied over a 2 mm glass fiber reinforced polymer (GRP) sublayer+2 thick 20 psi foam insulation material formed according to the present disclosure (in the present embodiment comprising a 2 thick substrate of a polyisocyanurate insulation material with a minimum compressive strength of 20 psi, having a glass fiber reinforced polymer (GRP) sublayer applied thereto), and a 1.5 thick 20 psi foam insulation material positioned on a plywood roof deck, and without having a coverboard (shown in the center column). This roofing system was compared to an example roofing system (shown in the left column) including a 60 mil TPO single ply membrane applied over a 0.63 () thick gypsum coverboard, such as used in conventional roofing systems, and a 1.5 thick 20 psi foam insulation positioned on a plywood roof deck; and to another roofing system (shown in the right column) including a 60 mil TPO single ply membrane applied over a 0.5 thick 80 psi foam insulation material (a high density foam insulation material having a minimum compressive strength of 80 psi), and a 1.5 thick 20 psi foam insulation material positioned on a plywood roof deck.

[0175] Each of the roofing systems shown in FIG. 8, was subjected to impact test conditions in accordance with the FM 4473 testing standard for Very Severe Hail Resistance, during which the roofing systems were impacted with 2-inch ice balls propelled at 152-160 feet per second, with the ice balls striking the roofing systems with an impact force or energy of approximately 80J (58 ft-lb). As indicated in the photos in the left column, the roofing system including the 0.63 () gypsum coverboard showed signs of damage after impact with a 2 ice ball, including indentions formed within the upper surface of the membrane (shown in the top photo in the left column) and damage, including cracking, of the coverboard itself (shown in the lower photo of the left column). The roofing system including the 0.5 80 psi foam insulation likewise showed visible damage in the form of deep depressions (shown in the photos of the right column). By contrast, as shown by the photos in the center column of FIG. 8, the roofing system formed according to the principles of the present disclosure, including the 2 mm GRP+2 foam insulation material without a coverboard, showed minimal impressions or signs of impact and no substantial signs of cracking as found with the other roofing systems including either a coverboard or a 0.5 80 psi high density foam insulation.

[0176] In addition, FIG. 9 illustrates the results of a comparison test of modified bitumen roofing systems, including an example roofing system having a coverboard (a 0.5 thick gypsum fiber coverboard) and a modified bitumen membrane material, versus a modified bitumen roofing system constructed in accordance with the principles of the present disclosure, including a glass fiber reinforced polymer composite (GRP) insulation material without a coverboard.

[0177] The conventional roofing system example (shown on the left) included a 0.5 thick plywood deck, a 1.5 20 psi foam insulation material applied over the plywood deck, a 0.5 gypsum coverboard adhered to the upper surface of the 1.5 20 psi foam insulation, and a modified bitumen material (including an asphaltic base sheet and an asphaltic cap sheet attached to the base sheet with an adhesive) attached to the upper surface of the coverboard with a cold applied membrane adhesive. A plurality of granules further was adhesively attached to the upper surface of the cap sheet of the two-ply modified bitumen material. The roofing system formed according to the principles of the present disclosure (shown on the right) did not include a coverboard, and comprised a 0.5 plywood deck, a 1.5 20 psi foam insulation applied over the plywood deck, a reinforced insulation material including a 2 mm GRP+2 20 psi foam insulation material, formed in accordance with embodiments of the present disclosure, applied to the upper surface of the 1.5 20 psi foam insulation material, and a modified bitumen material (including an asphaltic base sheet and an asphaltic cap sheet attached to the base sheet with an adhesive) attached to the upper surface of the reinforced insulation panel with a cold applied membrane adhesive material. In addition, a plurality of granules was adhesively attached to the upper surface of cap sheet of the modified bitumen material.

[0178] Both roofing systems were subjected to testing in accordance with the FM 4473testing standard for Very Severe Hail Resistance, during which the roofing systems were impacted by 2 ice balls propelled at 152-160 feet per second, the ice balls striking the roofing systems with an impact force or energy of approximately 80J (58 ft-lb). As can be seen in FIG. 9, the conventional roofing system using a coverboard showed visible impact damage in the form of holes and deep depressions in the exposed surface thereof. By contrast, the roofing system formed according to the principles of the present disclosure, using a 2 mm GRP+2 20 psi foam insulation material, and without using a coverboard, showed minimal visible impact damage.

[0179] The foregoing description generally illustrates and describes various embodiments of the present disclosure. It will, however, be understood by those skilled in the art that various changes and modifications can be made to the above-discussed construction of the present disclosure without departing from the spirit and scope of the present disclosure as disclosed herein, and that it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as being illustrative, and not to be taken in a limiting sense. Furthermore, the scope of the present disclosure shall be construed to cover various modifications, combinations, additions, alterations, etc., above and to the above-described embodiments, which shall be considered to be within the scope of the present disclosure. Accordingly, various features and characteristics of the present disclosure as discussed herein may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the present disclosure, and numerous variations, modifications, and additions further can be made thereto without departing from the spirit and scope of the present disclosure.