POUR IN PLACE INSULATING FOAM

Abstract

Some embodiments of the present technology may encompass pour in place roofing insulation systems. The insulation systems may include an upper roof surface material that is configured to be vertically spaced apart from the top surface of the roofing structure. The insulation systems may include a plurality of expansion limiters that are configured to extend between the roofing structure and the upper roof surface material. The insulation systems may include a polyiso foam insulation material that is configured to be disposed between and filling at least substantially all vertical space between the roofing structure and the upper roof surface material.

Claims

1. A pour in place roofing insulation system, comprising: an upper roof surface material that is configured to be vertically spaced apart from a top surface of a roofing structure; a plurality of expansion limiters that are configured to extend between the roofing structure and the upper roof surface material; and a polyiso foam insulation material that is configured to be disposed between and filling at least substantially all vertical space between the roofing structure and the upper roof surface material.

2. The pour in place roofing insulation system of claim 1, wherein: each of the plurality of expansion limiters comprises one or both of a string and a wire.

3. The pour in place roofing insulation system of claim 1, wherein: each of the plurality of expansion limiters comprises a vertical standoff.

4. The pour in place roofing insulation system of claim 3, wherein: a length of each vertical standoff is adjustable.

5. The pour in place roofing insulation system of claim 1, wherein: at least some of the plurality of expansion limiters comprise different lengths such that a vertical distance between the roofing structure and the upper roof surface material varies across an area of the roofing structure.

6. The pour in place roofing insulation system of claim 1, wherein: the upper roof surface comprises a roofing coverboard.

7. The pour in place roofing insulation system of claim 1, wherein: the polyiso foam insulation material comprises an open cell foam.

8. The pour in place roofing insulation system of claim 1, further comprising: the roofing structure, wherein: the upper roof surface material is vertically spaced apart from a top surface of the roofing structure; the plurality of expansion limiters extend between the roofing structure and the upper roof surface material; and the polyiso foam insulation material is disposed between and fills at least substantially all vertical space between the roofing structure and the upper roof surface material.

9. A pour in place roofing insulation system, comprising: an upper roof surface material that is configured to be vertically spaced apart from a top surface of a roofing structure; at least one vertical support member that is configured to extend at least partially between the roofing structure and the upper roof surface material; and a closed cell polyiso foam insulation material that is configured to be disposed between and filling substantially all vertical space between the roofing structure and the upper roof surface material.

10. The pour in place roofing insulation system of claim 9, wherein: each of the at least one vertical support member comprises a corrugated material.

11. The pour in place roofing insulation system of claim 9, wherein: each of the at least one vertical support member comprises a honeycomb structure defining a plurality of cells.

12. The pour in place roofing insulation system of claim 11, wherein: each of the at least one vertical support member is oriented such that a length of each of the plurality of cells extends in a vertical direction relative to the roofing structure.

13. The pour in place roofing insulation system of claim 11, wherein: each of the at least one vertical support member is moveable between a collapsed position in which each of the plurality of cells is substantially closed and a support position in which each of the plurality of cells is substantially open.

14. The pour in place roofing insulation system of claim 11, wherein: the polyiso foam insulation material at least substantially fills each of the plurality of cells.

15. The pour in place roofing insulation system of claim 9, wherein: the at least one vertical support member defines a plurality of voids that are at least substantially filled by the polyiso foam insulation material.

16. A method of installing a roofing insulation system, comprising: positioning one or more insulation height members atop a roofing structure, wherein a height of the one or more insulation height members setting a final height of the roofing insulation system; positioning an upper roof surface material above the one or more insulation height members; and pouring a polyiso foam between the roofing structure and the upper roof surface material such that the polyiso foam fills at least substantially all vertical spaced between the roofing structure and the upper roof surface material.

17. The method of installing a roofing insulation system of claim 16, wherein: the one or more insulation height members comprise one or both of a string and a wire; and upon being poured, the polyiso foam expands to lift the upper roof surface away from the roof structure until the one or both of the string and the wire are taut to set a thickness of the polyiso foam.

18. The method of installing a roofing insulation system of claim 17, wherein: the polyiso foam is introduced between the roofing structure and the upper roof surface material through an opening formed in the upper roof surface material.

19. The method of installing a roofing insulation system of claim 16, wherein: the one or more insulation height members comprise a honeycomb structure defining a plurality of cells; and pouring the polyiso foam comprises introducing the polyiso foam into each of the plurality of cells.

20. The method of installing a roofing insulation system of claim 16, wherein: at least some of the one or more height adjustment members comprise different lengths such that a vertical distance between the roofing structure and the upper roof surface material varies across an area of the roofing structure.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] A further understanding of the nature and advantages of various embodiments may be realized by reference to the following figures. In the appended figures, similar components or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label by a dash and a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.

[0009] FIG. 1 illustrates a roof insulation system according to embodiments of the present invention.

[0010] FIG. 2 illustrates a roof insulation system according to embodiments of the present invention.

[0011] FIG. 3 illustrates a roof insulation system according to embodiments of the present invention.

[0012] FIG. 3A illustrates a sheet of a vertical support member according to embodiments of the present invention.

[0013] FIG. 3B illustrates a vertical support member formed from multiple sheets according to embodiments of the present invention.

[0014] FIG. 3C illustrates the vertical support member of FIG. 3B in an open position according to embodiments of the present invention.

[0015] FIG. 3D illustrates the vertical support member of FIG. 3B in a collapsed position according to embodiments of the present invention.

[0016] FIG. 4 is a flowchart of a process for insulating a roof structure according to embodiments of the present invention.

DETAILED DESCRIPTION

[0017] The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described.

[0018] Embodiments of the present invention are directed to pour in place insulation systems for roofing applications. The insulation systems may provide alternative solutions to conventional polyiso foam insulation boards and may significantly reduce the volume of insulation materials to be shipped to a job site. For example, conventional roofing insulation systems involve stacking a number of layers of polyiso and/or other insulation boards (which often have thicknesses of between about 0.25 inches and 4 inches) to produce an insulation layer of sufficient thickness to provide a desired R value. In some instances, the thickness of the insulation layer may be up to 18 inches, which may result in thousands of insulation boards being shipped for larger buildings. Some embodiments of the present invention may utilize a single layer of insulation boards (i.e., short or no stacks of insulation boards), which may greatly reduce (e.g., up to 72x where quarter inch insulation boards are used) the number of boards needed to be shipped to a construction site. Embodiments may utilize a combination of a single layer of insulation boards (or other upper roof surface material) and pour in place foam insulation to generate a roofing insulation system having a sufficiently high R value. The reduction in roofing boards may reduce the shipping volume, with the eliminated roofing boards being replaced by more dense foam-producing chemicals. Embodiments may also reduce the thickness of the final insulation layer, as the pour in place insulation may have a higher R value per inch than existing insulation boards due to the more uniform cellular foam structure within the pour and place insulation that may be attributed to the lack of discontinuities of insulation board surfaces when boards are stacked atop one another.

[0019] Turning now to FIG. 1, one embodiment of a pour in place insulation system 100 is illustrated. Insulation system 100 may include a roof structure 102, such as a roof deck, which may be formed from various materials such as, but not limited to, steel, concrete, cement and/or wood. Roof structure 102 may serve as a primary substrate on which various insulation and/or weatherproofing layers are supported. Insulation system 100 may include an insulation layer 104, which may be disposed atop a top surface of the roof structure 102. The insulation layer 104 may include a polyisocyanurate (polyiso) foam material that has been poured and cured atop the roof structure 102. The polyiso foam may be a low rise foam and/or a high rise foam and may be a closed cell and/or open cell foam in various embodiments. The polyiso foam may be provided as a single and/or continuous layer of foam in some embodiments, which may enable the insulation layer 104 to be generally uniform across a thickness of the insulation layer 104, without the discontinuities associated with the interfaces between stacked insulation boards used in conventional roof insulation. This results in a more consistency in cellular structure and may enable the R-value per inch of the insulation layer 104 to be greater than that of conventional insulation boards. This may enable the insulation layer 104 to be thinner than in conventional roof insulation systems, while still providing the same level of thermal insulation. Due to the uniformity of the insulation layer 104, embodiments may also provide improved air and vapor sealing than conventional roof insulation systems.

[0020] The thickness of the insulation layer 104 may determine the final shape of the roof. The insulation layer 104 may be between about 0.5 and 18 inches thick. In some embodiments, the roof may be substantially flat. In such embodiments, the thickness of the insulation layer 104 may be substantially constant across the area of the roof. For example, the thickness of the insulation layer 104 may be uniform to within 10%, to within 5%, to within 3%, to within 1%, to within 0.5%, or less. In other embodiments, the roof may include one or more contoured areas, tapered areas, and/or stepped regions of different heights. In such embodiments, the thickness of the insulation layer 104 may be varied across the area of the roof structure. It will be appreciated that any shape of roof (e.g., flat, tapered, stepped, contoured, etc.) may be generated by controlling the thickness of the insulation layer 104.

[0021] The polyiso foam may be a low density foam or a high density foam, depending on the application, as will be discussed below. For example, the density of the polyiso foam may be between about 0.5 pcf and 7 pcf. The polyiso foam may be an open cell foam or a closed cell foam and may be a high lift foam or a low lift foam based on the needs of a particular application.

[0022] The polyiso foam may be formed from a mixture of an isocyanate and a polyol. For example, polyfunctional isocyanates that may form substituted or unsubstituted polyisocyanates that are used to make the polyiso foam and other foam products include aromatic, aliphatic, and cycloaliphatic polyisocyanates having at least two isocyanate functional groups. Exemplary aromatic polyfunctional isocyanates include: 4,4-diphenylmethane diisocyanate (MDI), polymeric MDI (PMDI), toluene disisocyanate, and allophanate modified isocyanate. For example, the polyfunctional isocyanate may be PMDI with functionality between 2.3 to 3.0, viscosity less at 800 cps at 25 C., and isocyanate content between 28% to 35%.

[0023] The polyfunctional isocyanates may be reacted with a polyfunctional co-reactant that has at least two reactive groups that react with the polyfunctional isocyanate to produce a polyisocyanurate compounds for the present products. Exemplary polyfunctional co-reactants may include polyester and polyether polyols having at least 2 isocyanate reactive groups, such as hydroxyl groups. Specific examples include aromatic polyester polyols which have good mechanical properties, as well as hydrolytic and thermo-oxidative stability. Commercially available polyester polyol include those sold by Stepan Company under the name Stepanol and those sold by Huntsman Corporation under the name of Terol. Exemplary polyols may have a functionality between 2 and 2.5 and hydroxyl number between 150 mg KOH/gm and 450 mg KOH/gm.

[0024] The catalysts used to polymerize the polyisocyanurates may include amine catalysts and metal catalysts, among other catalysts. The amine catalysts catalyze both urethane reactions between isocyanates and polyols, and urea reactions between water and isocyanates. The metal catalysts may include metal carboxylate trimer catalysts, which promote the conversion of isocyanate to highly thermally stable isocyanurate ring. Examples of suitable amine catalysts include pentamethyldiethylenetriamine (PMDETA), dimethylcyclohexylamine, and 1, 3, 5-tris (3-(dimethylamino) propyl)-hexahydro-triazine. Examples of suitable metal catalysts include potassium octoate and potassium acetate.

[0025] The present polyisocyanurate formulations may also include one or more surfactants. The surfactants function to improve compatibility of the formulation components and stabilize the cell structure during foaming. Exemplary surfactants can include organic or silicone based materials. Typical silicone based surfactants may include polyether modified polysiloxane, such as commercially available DC193 surfactant from AirProducts, and Tergostab series surfactants from Evonik, such as Tergostab 8535.

[0026] The polyol typically includes either or both a polyether and polyester having a hydroxyl number between about 25 and 500, and more commonly between about 200 and 270. The hydroxyl number is a measure of the concentration of the hydroxyl group in the polyol, which is expressed as the milligrams of KOH (potassium hydroxide) equivalent to the hydroxyl groups in one gram of polyol. Polyether is commonly not used in conventional polyisocyanurate foam boards because it is typically less flame resistant than the aromatic polyester that is used in such boards. A lower hydroxyl number commonly results in longer polymer chains and/or less cross linking, which results in a relatively loose polymer chain. In contrast, a higher hydroxyl number commonly results in more cross linking and/or shorter polymer chains, which may provide enhanced mechanical properties and/or flame resistance.

[0027] An isocyanurate is a trimeric reaction product of three isocyanates forming a six-membered ring. The ratio of the equivalence of NCO groups (provided by the isocyanate-containing compound or A-side) to isocyanate-reactive groups (provided by the isocyanate-containing compound or B side) may be referred to as the index or ISO index. When the NCO equivalence to the isocyanate-reactive group equivalence is equal, then the index is 1.00, which is referred to as an index of 100, and the mixture is said to be stoichiometrically equal. As the ratio of NCO equivalence to isocyanate-reactive groups equivalence increases, the index increases. Above an index of about 150, the material is generally known as a polyisocyanurate foam, even though there are still many polyurethane linkages that may not be trimerized. When the index is below about 150, the foam is generally known as a polyurethane foam even though there may be some isocyanurate linkages.

[0028] The polyiso foam may have an isocyanate index greater than about 200, commonly between about 200 and 300, and more commonly between about 250 and 270. When isocyanate reacts with one or more polyols to form polyurethane, one NCO group reacts with one OH group. As is known in the art, the index is defined as the ratio of NCO group to OH group multiplied by 100 as shown in the formula below:

[00001]$\mathrm{Index}=\frac{\mathrm{Moles}\mathrm{of}\mathrm{NCO}\mathrm{group}}{\mathrm{Moles}\mathrm{of}\mathrm{OH}\mathrm{group}}100$

[0029] When the number of NCO group equals the number of OH group in a formulation, a stoichiometric NCO:OH ratio of 1.0 is realized and a polyurethane polymer/foam is produced. When the number of NCO groups is significantly more than the number of OH groups in a formulation, the excess isocyanate group reacts with itself under catalytic condition to form isocyanurate linkage and polyisocyanurate foam is produced. The above described isocyanate index, and especially an index of between about 250 and 270, provides at least a 2:1 ratio of NCO groups to OH groups, which has been found to provide an appreciable combination of structure integrity, thermal strength and/or stability, and fire resistance. In some embodiments, the isocyanate index may be between 250-300.

[0030] In some embodiments, the polyiso foam may include between 1 and 10 weight percent of a hydrocarbon blowing agent, such as n-pentane, iso-pentane, cyclopentane, and their blends. In an exemplary embodiment, the polyiso foam may include between 5 and 8 weight percent of the hydrocarbon blowing agent. The weight percent of the hydrocarbon blowing agent typically corresponds with the foam density of the polyiso foam with lower density foam boards (e.g., insulation boards) having a higher weight percentage of the hydrocarbon blowing agent than more dense foam boards (e.g., roofing cover boards). For example, insulation boards having a density of between about 1.5 and 2.5 pounds per cubic foot (lbs/ft.sup.3), commonly have 5% or more of a hydrocarbon blowing agent by weight, and more commonly between about 6 and 7 weight percent. In contrast, roofing cover boards that have a density of up to 10 lbs/ft.sup.3, and more commonly between 6 and 7 lbs/ft.sup.3, commonly have less than 5% of a hydrocarbon blowing agent by weight, and more commonly between about 1.5 and 3 weight percent. In some embodiments, the polyiso foam may include other substances.

[0031] The insulation system 100 may include an upper roof surface material 106, which may be vertically spaced apart from the top surface of the roofing structure and may serve as an upper and/or uppermost surface of the roof. For example, the upper roof surface material 106 may be disposed atop the insulation layer 104. The upper roof surface material 106 may include one or more layers. For example, the upper roof surface material 106 may include a rigid member, such as a construction and/or insulation board and/or a waterproofing barrier, such as a roofing membrane. Other layers may be present in some embodiments. In a particular embodiment, a construction board may be covered by a roofing membrane. The rigid members may include polyisocyanurate, oriented strand board, gypsum, and/or other roofing boards and/or may include insulation boards (such as polyiso foam insulation boards. Oftentimes, the rigid member may have a thickness of between about 0.25 inches and 2 inches, more commonly between about 0.25 inches and 1 inch, and even more commonly between about 0.25 inches and 0.5 inches. The use of a rigid material may help constrain the flow and/or expansion of polyiso foam to ensure that the insulation layer 104 has a desired thickness and shape. A lowermost layer of the upper roofing surface material 106 may be secured to the roof structure 102 via the foam of the insulation layer 104, without the use of any adhesives and/or fasteners in some embodiments. For example, during insulation (prior to the foam curing), an underside of the upper roofing surface material 106 and a top surface of the roof structure 102 may contact the uncured foam. The tackiness of the uncured foam may bond with the underside of the upper roofing surface material 106 and a top surface of the roof structure 102 to secure the insulation system 100 components together. The waterproofing barrier may be a roofing membrane, such as a single ply membrane. The term single-ply may be used to describe a roof structure having a single application of a roofing membrane, but the roofing membrane itself may include multiple layers. For example, the roofing membrane may include polymer layers, reinforcing layers, adhesive layers, coatings, a fleece layer, and the like. It will be appreciated that in some embodiments, multiple layers of roofing membrane may be applied to a single roof structure.

[0032] In some embodiments, roofing membrane may include one or more polymeric membranes and/or other waterproofing layer. For example, a polymeric membrane may form the outer layer of the roof once fully installed, and may help prevent leaks in the roofing structure and provides aesthetic appeal to the finished roof. For example, the waterproofing layer often provides a uniform outer surface that provides an aesthetically pleasing finished appearance to the roof. Polymeric membrane may have a white exterior, but may be made in various other colors or shades, such as grey, tan, black, and the like. White polymeric membranes are often used to provide a pleasing appeal to the building and/or to reflect radiation and thereby minimize heat island effects. In other embodiments, a black or other dark polymeric membrane may be provided. Such polymeric membranes absorb more radiant heat than white polymeric membranes. Additionally, in the winter, condensation evaporates quicker and snow and ice melt more rapidly on black roofs than white roofs.

[0033] In some embodiments, polymeric membranes may be formed of various synthetic rubber materials, modified bitumen, or thermoplastic materials. For example, roofing membrane 106 may commonly include thermoplastic polyolefin (TPO), polyvinyl chloride (PVC), ethylene propylene diene monomer (EPDM), chlorinated polyethylene (CPA), and/or modified bitumen, although some embodiments may use other thermoset and/or thermoplastic roofing membranes. In some embodiments, the polymeric membrane may include one or more polymers blended with one or more fillers. For example, in some embodiments the polymeric membranes may include some combination of the following materials: polypropylene, polyethylene, block copolymer polypropylene, rubber, plasticizers, fiberglass, carbon fiber, fire retardants, and the like. In another embodiment, a polymeric membranes may have a more pure polymer blend without or with very few fillers. For example, the polymeric membrane may include mainly polypropylene or polyethylene or some combination of these polymers with little to no fillers, although in some embodiments, these polymeric membranes may include some amount of a filler, such as a fire retardant. In some embodiments, the polymeric membrane may have a thickness of between about 500 m to about 3 mm, however other thicknesses are possible in various embodiments.

[0034] Insulation system 100 may include a number of insulation height members 108, which may help limit, set, and/or otherwise determine a final thickness of the insulation layer 104 and insulation system as a whole. The insulation height members 108 may be disposed between the roofing structure 102 and the upper roofing surface material 106, with the insulation layer 104 filling the volume between the insulation height members 108. In some embodiments, the insulation height members 108 may be coupled with the roofing structure 102 and/or the upper roofing surface material 106. The insulation height members 108 may all have the same height to generate an insulation layer 104 having a substantially flat top surface, or may have different heights to create a sloped, tapered, stepped, and/or otherwise non-planar roofing surface. As will be discussed in greater detail below, the insulation height members 108 may include expansion limiters that limit the vertical expansion of the poured foam to a set height to determine a final thickness of the insulation layer 104. The expansion limiters may be rigid members that may support the upper roofing surface material 106 and/or help determine a final thickness and/or shape of the roof. In some embodiments, the expansion limiters may be flexible materials, such as string, rope, wire, cable, etc., which may be coupled with the upper roofing surface material 106 to prevent the poured foam from rising beyond a length of the expansion limiter. The insulation height members 108 may include vertical support members that may be sized and/or stacked atop one another to provide a foundation of sorts to constrain the flow and expansion of the foam prior to the foam setting. In some embodiments, the vertical support members may define open interiors that may be filled with foam to create a substantially uniform insulation layer 104 between the roofing structure 102 and the upper roofing surface material 106.

[0035] FIG. 2 illustrates one embodiment of a pour in place insulation system 200. Insulation system 200 may be similar to insulation system 100 and may be understood to include any of the features described in relation to insulation system 100 in some embodiments. Insulation system 200 may include a roof structure 202, an insulation layer 204, an upper roofing surface material 206, and a number of insulation height members, which may be disposed atop a top surface of the roof structure 202. In the present embodiment, each of the insulation height members may be in the form of an expansion limiter 208, which may extend between and couple the roof structure 202 and the upper roof surface material 206 and may control the vertical expansion of the polyiso foam. The expansion limiters 208 may include rigid and/or flexible members. For example, in some embodiments, the expansion limiters 208 may include rigid members, such as screws, poles, posts, vertical standoffs (which may have a set and/or adjustable length), boards, and/or other rigid components. A base of each rigid expansion limiter 208 may be coupled with a top end of the roof structure 202, while a top surface of each rigid expansion member 208 may be coupled with the upper roofing surface material 206. For example, the top end of each rigid expansion limiter 208 may be fastened, adhered, and/or otherwise coupled with an underside of the upper roof surface material 206 (such as a roofing board). The rigid expansion limiters 208 may support the upper roofing surface material 206 at a desired height relative to the roof structure 202 to control a shape of the final roof and a thickness of the insulation layer 204. To provide a flat roof (and insulation layer 204 of uniform thickness), the rigid expansion limiters 208 may each have substantially the same length. The length of one or more rigid expansion limiters 208 may be varied to provide an insulation layer 204 with a variable thickness to create a tapered, sloped, contoured, stepped, and/or otherwise non-planar roof.

[0036] In some embodiments, such as illustrated in FIG. 2, the expansion limiters 208 may include flexible members, such as wires, ropes, cables, strings, and/or other flexible components. One end of each flexible expansion member 208 may be tied, adhered, fastened, and/or otherwise coupled with the roof structure 202, while an opposite end of the flexible expansion member 208 may be tied, adhered, fastened, and/or otherwise coupled with the upper roofing surface material 206. In one embodiment, a portion of the flexible expansion limiter 208 may be inserted through a hole formed in the upper roofing surface material 206 and tied off and/or otherwise secured to and/or against an upper surface of the upper roofing surface material 206, upper roofing surface material 206. Once coupled between the roof structure 202 and the upper roofing surface material 206, the flexible expansion limiters 208 may remain slack, with the upper roofing surface material 206 being positioned close to the roof structure 202, until the polyiso foam is poured. The pouring, and subsequent expansion, of the foam, may lift the upper roofing surface material 206 upward away from the roof structure 202 until the flexible expansion limiters 208 are substantially taut (such as when the foam fills at least substantially all vertical space between the roof structure 202 and the upper roof surface material 206. Once taut, the flexible expansion limiters 208 may prevent the further vertical displacement of the upper roofing surface material 206 and may constrain the foam. The foam may also flow laterally about the expansion limiters 208 to fill substantially all of the volume between the roof structure 202 and the upper roofing surface material 206. The flexible expansion limiters 208 may limit the expansion of the foam to ensure that the upper roofing surface material 206 upward is positioned at a desired height relative to the roof structure 202 once the foam is poured and set to control a shape of the final roof and a thickness of the insulation layer 204. To provide a flat roof (and insulation layer 204 of uniform thickness), the flexible expansion limiters 208 may each have substantially the same length. The length of one or more flexible expansion limiters 208 may be varied to provide an insulation layer 204 with a variable thickness to create a tapered, sloped, contoured, stepped, and/or otherwise non-planar roof.

[0037] In some embodiments, a plate 210, such as an annular and/or generally rectangular plate, may be provided against the upper surface of the upper roofing surface material 206. The flexible expansion limiter 208 may be inserted through a central aperture of the plate 210 and coupled with the plate 210. The plate 210 may help distribute tension forces across a larger area of the upper roofing surface material 206 such that when the flexible expansion limiter 208 is taut and/or otherwise under tension (such as due to the expansion of the foam), the upper end of the flexible expansion limiter 208 is prevented from being pulled through the upper roofing surface material 206. This may ensure that the flexible expansion limiter 208 remains secured to the upper roofing surface material 206 and may maintain the upper roofing surface material 206 at a desired vertical distance relative to the roof structure 202 to generate a desired roof profile. Each plate 210 may have a diameter (or other lateral dimension) of at least or about 0.5 inches, at least or about 1 inch, at least or about 2 inches, at least or about 3 inches, or greater. A similar plate may be utilized in conjunction with rigid expansion limiters, with a fastener being inserted through an aperture in the plate before being inserted through a portion of the top end of the rigid expansion limiter. A flange of the fastener may prevent the fastener from pulling through the aperture, which may ensure that expansion of the foam does not pull the fastener through the upper roofing surface material 206.

[0038] The polyiso foam in insulation layer 204 may be a high lift foam, such as an open cell foam in some embodiments, which may deliver greater expansion than close cell foams. However, some embodiments may utilize a closed cell foam. The foam may have a density of between about 0.5 pcf and 7 pcf and an R value per inch of between about 3.0 and 8.0 The polyiso foam may be formed from (i) a polyisocyanate reactant and (ii) a polyol reactant. The polyiso foams may be made by combining separate liquid mixtures that include the polyisocyanates (the A-side mixture) and the polyols (the B-side mixture). In some embodiments, the A-side mixture may be a two component methylene diisocyanate (MDI) based polyurethane. In embodiments, the first component of the two component foam may be or include a polymeric isocyanate containing reactive isocyanate groups. The second component may be a combination of polyols, catalytic agents, and/or a blowing agent such as, for example, HFO 1233zd, HFC-245fa, HFC-365mfc, water, and the like. In some embodiments, the B-side component of the pour-in-place insulation material may include between about 0 wt. % and about 70 wt. % polyester polyol, between about 0 wt. % and about 70 wt. % polyether polyol, between about 5 wt. % and about 15 wt. % flame retardant, between about 0.3 wt. % and about 3 wt. % catalyst, between about 1 wt. % and about 3 wt. % surfactant, between about 0 wt. % and about 3 wt. % additive, between about 1 wt. % and about 3 wt. % water, and between about 5 wt. % and about 15 wt. % HFC/HFO. Examples of such pour-in-place insulation materials may be or include PIP Foam 250A and PIP Foam 50 manufactured by Huntsman and ENVELO-POUR-SFC-I-2.0-CG polyurethane pour foam manufactured by SPI.

[0039] The insulation system 200 may provide a continuous layer of insulation having a relatively smooth top surface (such as the top surface of a roofing board). The smooth surface may facilitate easier and/or better installation of a roofing membrane. The insulation system 200 may provide better air and vapor sealing than conventional roof insulation systems. Additionally, the insulation system 200 may provide an effective means to build slope and/or other non-planar features into a roof.

[0040] FIG. 3 illustrates one embodiment of a pour in place insulation system 300. Insulation system 300 may be similar to insulation system 100 and 200 and may be understood to include any of the features described in relation to insulation system 100 and 200 in some embodiments. Insulation system 300 may include a roof structure 302, an insulation layer 304, an upper roofing surface material 306, and a number of insulation height members, which may be disposed atop a top surface of the roof structure 302. In the present embodiment, each of the insulation height members may be in the form of a vertical support member 308, which may extend at least partially between the roof structure 302 and the upper roof surface material 306. Each vertical support member 308 may be self-standing atop the roof structure 302. Each vertical support member 308 may include a single row of vertical structures or multiple structures coupled together. The vertical support members 308 may be stacked in some embodiments, with one or more layers of vertical support members 308 being used to at least partially determine a height and shape of the insulation layer 304 and resultant roof. The vertical support members 308 may be formed of various materials, such as wood, metal, plastic, and the like. In some embodiments, the vertical support members 308 may not be load bearing, but instead may only be used to constrain and build the height of the foam to a desired level as the foam is poured and cured, with the set foam providing the load-bearing capability of the finished roof. For example, the vertical support members 308 may be formed from paper, cardboard, construction paper, polyethylene strips, and/or other materials that may not provide significant load bearing properties.

[0041] In some embodiments, each vertical support member 308 may include one or more corrugated and/or otherwise non-linear structures that may enable the vertical support members 308 to be self-standing and readily stacked. Spaces and/or other voids between the structures may be filled with the foam insulation layer 304. In some embodiments, such as illustrated in FIG. 3, the vertical support members 308 may include honeycomb structures that define one or more cells 310. The cells 310 may be fully bound along at least one direction. For example, the cells 310 may be aligned vertically (with walls that define each cell extending at least partially between the roof structure 302 and the upper roofing surface material 306) and/or horizontally (with wall that define each cell extending in a generally horizontal direction). As illustrated, the cells 310 are each oriented vertically, with a length of each cell 310 extending in a vertical direction relative to the roof structure 302. A cross-section of each cell 310 may have any enclosed cross-sectional shape, such as circular, elliptical, triangular, rectangular, hexagonal, and/or other shape. In some embodiments, the honeycomb structures may be moveable between a collapsed position in which each cell 310 is substantially closed and a support position in which each cell 310 is substantially open as illustrated. For example, as illustrated in FIGS. 3A-3D, a vertical member 308 may include a number of sheets 312 that are coupled together to form a grid. In some embodiments, each sheet 312 may include a number of slits 314 that each extend at least partially through the sheet 312 as shown in FIG. 3A. Sheets 312a arranged in a first direction may be positioned with the slits 314 at a top end of the sheet 312a, while sheets 312b arranged in a second direction may be positioned with the slits 314 at a bottom end of the sheet 312b. This may enable the sheets 312a to be pivotally coupled with one another by aligning a slit 314 of a sheet 312a with a slit 314 from a sheet 312b as shown in FIG. 3B. In the support position, the sheets 312a and 312b may be pivoted to open the cells 310 as shown in FIG. 3C. In the collapsed position, the sheets 312a and 312b may be pivoted to position the sheets 312a and 312b close to one another to fully or substantially close the cells 310 as illustrated in FIG. 3D. Collapsible vertical support members 308 may take up less space than fixed members, and may therefore further reduce the shipping and storage requirements to produce the insulation system 300.

[0042] Foam may be poured within cells 310 and/or other gaps and voids between the vertical support members 308 until the foam at least substantially fills each of the cells. 310 and/or otherwise fills substantially all vertical space between the roof structure 302 and the upper roof surface material 306. The number (when stacked) and/or height of vertical support members 308 may be varied across the roof to provide an insulation layer 304 with a variable thickness to create a tapered, sloped, contoured, stepped, and/or otherwise non-planar roof. Any number of vertical support members 308 may be stacked to produce an insulation layer 304 of a desired thickness.

[0043] The polyiso foam in insulation layer 304 may be a low lift foam, such as a closed cell foam in some embodiments, which may deliver greater rigidity than open cell foams. The increased rigidity may provide greater structural support than open cell foams, which may enable the insulation layer 304 to provide greater load bearing properties. Such foams may also flow better than open cell foams and may self-level to generate a substantially flat upper surface. In some embodiments, the flat upper surface may enable a roofing membrane to be positioned directly against the insulation layer 304, without any rigid boards. For example, the roofing membrane may form the upper roofing surface material 306 without a roofing board. The roofing membrane may be applied to the upper surface of the insulation layer 304 prior to the curing of the foam, which may enable the tack of the foam to adhere the roofing membrane. Some embodiments may still include a roofing board as all or part of the upper roofing surface material 306. The foam may have a density of between about 0.5 pcf and 7 pcf and an R value per inch of between about 3.0 and 8.0.

[0044] FIG. 4 is a flowchart illustrating a process 400 of installing a roofing insulation system according to embodiments of the present technology. Process 400 may be used to install pour in place polyiso foam roofing installation systems, including insulation systems 100, 200, and 300 described herein. Process 400 may begin at operation 405 by positioning one or more insulation height members atop a roofing structure, such as a roof deck. A height of each insulation height member may at least partially set and/or otherwise determine a final height of the roofing insulation system. For example, in some embodiments the insulation height members may include expansion limiters (such as expansion limiters 208) that prevent poured foam from rising and/or otherwise expanding above a certain level. In such embodiments, poured foam may rise until reaching the limit of the expansion limiters, at which point the foam will contact the upper roofing surface material and may be constrained. In other embodiments the insulation height members may include vertical support members (such as vertical support members 308) that may constrain the foam and help build a final height of an insulation layer and the insulation system as a whole. In such embodiments, positioning the insulation height members may define cells and/or other voids that may receive the poured foam. The length of the insulation height members may be controlled to determine a thickness of the roof. In some embodiments, each insulation height member may have a same length to generate a flat roof. In other embodiments, at least some of the insulation height members may have different lengths and/or may be stacked such that a vertical distance between the roofing structure and the upper roof surface material varies across an area of the roofing structure to create a roof and/or insulation layer having a tapered, sloped, contoured, stepped, and/or otherwise nonplanar surface.

[0045] Process 400 may include positioning an upper roof surface material above the one or more insulation height members at operation 410. The upper roof surface material may include a rigid material, such as a construction and/or insulation board, and/or may include a roofing membrane, such as a single-ply roofing membrane. For example, in some embodiments that upper roof surface may include a construction board that is faced with a roofing membrane.

[0046] At operation 415, process 400 may include pouring a polyiso foam between the roofing structure and the upper roof surface such that the polyiso foam fills at least substantially all vertical spaced between the roofing structure and the upper roof surface material. For example, where the insulation height members include expansion limiters, a high rise polyiso foam may be poured and/or otherwise supplied to a volume between the roofing structure and the upper roof surface material. If the expansion limiters are formed from rigid members, such as stanchions, poles, screws, set-offs, etc., the upper roof surface material may be fixed at a desired height relative to the roofing structure using the rigid expansion limiters. In such instances, the polyiso foam may be introduced to the volume between the roofing structure and the upper roof surface material until the polyiso foam presses against the bottom surface of the upper roof surface material (which is secured in place via the rigid expansion limiters) to set a height and surface contour of the polyiso foam insulation layer and, subsequently, the insulation system. If the expansion limiters are formed from flexible members, such as wires, strings, cables, etc., as the polyiso foam is introduced to the volume between the roofing structure and the upper roof surface material, the polyiso foam may rise and/or otherwise expand to lift the upper roof surface material away from the roof structure until the flexible expansion limiters are pulled taut. Once taut, the flexible expansion limiters may set a thickness and surface contour of the polyiso foam insulation layer and, subsequently, the insulation system, in a manner similar to the rigid expansion limiters.

[0047] In embodiments in which the insulation height members include vertical support members, the polyiso foam may be poured into voids, such as cells, formed within and/or between adjacent vertical support members. The vertical support members may constrain the polyiso foam within a desired area, and may help build the height of the insulation layer and the insulation system. For example, the walls of the vertical support members may prevent the polyiso foam from spreading laterally outward as the foam sets, which may also lead the polyiso foam to expand and/or flow upwards during pouring and/or rising of the foam. Polyiso foam may be poured until the vertical support members are covered to provide an insulation material of a given height. In embodiments in which the vertical support members include a honeycomb structure defining a number of cells, the polyiso foam may be introduced into each of the cells, which may help control the flow and expansion of the foam to generate an insulation layer having a desired thickness and/or contour.

[0048] In some embodiments the polyiso foam may be introduced from a top end of the volume between the roofing structure and the upper roof surface material. For example, one or more holes and/or other gaps may be provided within the upper roof surface material that enable the polyiso foam material to be introduced to the volume. In other embodiments, the polyiso foam may be provided laterally from one or more openings provided in a side between the roofing structure and the upper roof surface material.

[0049] Introducing the polyiso foam may include mixing an A-side and a B-side formulation and pouring, spraying, and/or otherwise applying the resultant foam mixture onto the roofing structure. The A-side and the B-side may be mixed prior to and/or during application of the foam onto the roofing structure. The reaction between the A-side and B-side formulations may generate the resultant foam, which may expand prior to curing. Once cured, the foam may have a density of between about 0.5 pcf and 7.0 pcf and may exhibit an R value per inch of between about 3.0 and 8.0. After pouring and/or curing the foam, one or more finishing operations may be performed on the roof. For example, a roofing membrane may be applied to the upper roofing surface material if not already present.

[0050] The methods, systems, and devices discussed above are examples. Some embodiments were described as processes depicted as flow diagrams or block diagrams. Although each may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be rearranged. A process may have additional steps not included in the figure. It will be further appreciated that all testing methods described here may be based on the testing standards in use at the time of filing or those developed after filing.

[0051] It should be noted that the systems and devices discussed above are intended merely to be examples. It must be stressed that various embodiments may omit, substitute, or add various procedures or components as appropriate. Also, features described with respect to certain embodiments may be combined in various other embodiments. Different aspects and elements of the embodiments may be combined in a similar manner. Also, it should be emphasized that technology evolves and, thus, many of the elements are examples and should not be interpreted to limit the scope of the invention.

[0052] Specific details are given in the description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. For example, well-known structures and techniques have been shown without unnecessary detail in order to avoid obscuring the embodiments. This description provides example embodiments only, and is not intended to limit the scope, applicability, or configuration of the invention. Rather, the preceding description of the embodiments will provide those skilled in the art with an enabling description for implementing embodiments of the invention. Various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the invention.

[0053] Having described several embodiments, it will be recognized by those of skill in the art that various modifications, alternative constructions, and equivalents may be used without departing from the spirit of the invention. For example, the above elements may merely be a component of a larger system, wherein other rules may take precedence over or otherwise modify the application of the invention. Also, a number of steps may be undertaken before, during, or after the above elements are considered. Accordingly, the above description should not be taken as limiting the scope of the invention.

[0054] Also, the words comprise, comprising, contains, containing, include, including, and includes, when used in this specification and in the following claims, are intended to specify the presence of stated features, integers, components, or steps, but they do not preclude the presence or addition of one or more other features, integers, components, steps, acts, or groups.

[0055] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly or conventionally understood. As used herein, the articles a and an refer to one or to more than one (i.e., to at least one) of the grammatical object of the article. By way of example, an element means one element or more than one element. About and/or approximately as used herein when referring to a measurable value such as an amount, a temporal duration, and the like, encompasses variations of +20% or +10%, +5%, or +0.1% from the specified value, as such variations are appropriate to in the context of the systems, devices, circuits, methods, and other implementations described herein. Substantially as used herein when referring to a measurable value such as an amount, a temporal duration, a physical attribute (such as frequency), and the like, also encompasses variations of +20% or +10%, +5%, or +0.1% from the specified value, as such variations are appropriate to in the context of the systems, devices, circuits, methods, and other implementations described herein.

[0056] As used herein, including in the claims, and as used in a list of items prefaced by at least one of or one or more of indicates that any combination of the listed items may be used. For example, a list of at least one of A, B, and C includes any of the combinations A or B or C or AB or AC or BC and/or ABC (i.e., A and B and C). Furthermore, to the extent more than one occurrence or use of the items A, B, or C is possible, multiple uses of A, B, and/or C may form part of the contemplated combinations. For example, a list of at least one of A, B, and C may also include AA, AAB, AAA, BB, etc.