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US-20260125905-A1 - Roofing System And Insulation Element For A Flat Roof Or A Flat Inclined Roof

US20260125905A1US 20260125905 A1US20260125905 A1US 20260125905A1US-20260125905-A1

Abstract

A roofing system for a flat roof or a flat inclined roof of a building with a thermal and/or acoustic insulation includes a structural support, a deck, a waterproof membrane, at least one insulation element being a bonded mineral fibre product made of mineral fibres, and a cured aqueous binder composition. The aqueous binder composition, prior to curing, comprises a component (i) in form of one or more oxidized lignins and a component (iia) in form of one or more modifiers. The insulation element has a bulk density between 70 kg/m3 and 250 kg/m3.

Inventors

  • Dorte Bartnik Johansson
  • Miroslav Nikolic

Assignees

  • ROCKWOOL A/S

Dates

Publication Date
20260507
Application Date
20260106

Claims (20)

  1. 1 - 17 . (canceled)
  2. 18 . A roofing system for a flat roof or a flat inclined roof of a building with a thermal and/or acoustic insulation, comprising a structural support, a deck, a waterproof membrane, at least one insulation element being a bonded mineral fibre product made of mineral fibres, and a cured aqueous binder composition, wherein the aqueous binder composition prior to curing comprises a component (i) in form of one or more oxidized lignins, a component (iia) in form of one or more modifiers, and wherein the insulation element has a bulk density between 70 kg/m 3 and 250 kg/m 3 .
  3. 19 . The roofing system according to claim 18 , wherein the roofing system comprises a vapour control layer.
  4. 20 . The roofing system according to claim 18 , wherein the mineral fibres are stone wool fibres.
  5. 21 . The roofing system according to claim 18 , wherein the insulation element has a loss on ignition (LOI) within the range of 2 to 8 wt.-%.
  6. 22 . The roofing system according to claim 18 , having insulation elements with a compression strength between 50 and 130 kPa measured in accordance with European Standard EN 826:2013.
  7. 23 . The roofing system according to claim 18 , having insulation elements with a delamination strength between 20 and 50 kPa measured in accordance with European Standard EN 1607:2013.
  8. 24 . The roofing system according to claim 18 , wherein component (i) is in form of one or more ammonia-oxidized lignins (AOL's).
  9. 25 . The roofing system according to claim 18 , wherein component (iia) comprises one or more modifiers selected from the group consisting of epoxidized oils based on fatty acid triglycerides.
  10. 26 . The roofing system according to claim 18 , wherein component (iia) comprises one or more modifiers selected from the group consisting of molecules having 3 or more epoxy groups.
  11. 27 . The roofing system according to claim 18 , wherein component (iia) comprises one or more flexible oligomer or polymer which contains reactive functional groups.
  12. 28 . The roofing system according to claim 27 , wherein the one or more flexible oligomer or polymer is selected from a low T g acrylic based polymer.
  13. 29 . The roofing system according to claim 27 , wherein the one or more flexible oligomer or polymer is a low T g vinyl based polymer.
  14. 30 . The roofing system according to claim 27 , wherein the one or more flexible oligomer or polymer is a low T g polyether.
  15. 31 . The roofing system according to claim 27 , wherein the reactive functional groups are selected from carbodiimide groups, anhydride groups, oxazoline groups, amino groups, and epoxy groups.
  16. 32 . The roofing system according to claim 18 , wherein component (iia) comprises one or more modifiers selected from β-hydroxyalkylamides and oxazolines.
  17. 33 . The roofing system according to claim 18 , comprising component (iia) in an amount of 1 to 40 wt.-%, based on the dry weight of component (i).
  18. 34 . The roofing system according to claim 18 , further comprising: a component (ii) in the form of one or more cross-linkers; and/or a component (iii) in the form of one or more plasticizers.
  19. 35 . The roofing system according to claim 34 , wherein the component (ii) comprises: one or more cross-linkers selected from β-hydroxyalkylamides and oxazolines; and/or one or more cross-linkers selected from the group consisting of polyethylene imine, polyvinyl amine, fatty amines; and/or one more cross-linkers in form of fatty amides; and/or one or more cross-linkers selected from the group consisting of dimethoxyethanal, glycolaldehyde, glyoxalic acid; and/or one or more cross-linkers selected from polyester polyols; and/or one or more cross-linkers selected from the group consisting of starch, modified starch, CMC; and/or one or more cross-linkers in form of aliphatic multifunctional carbodiimides; and/or one or more cross-linkers selected from melamine based cross-linkers.
  20. 36 . The roofing system according to claim 34 , wherein component (iii) comprises one or more plasticizers selected from the group consisting of polyethylene glycols, polyethylene glycol ethers, polyethers, hydrogenated sugars, phthalates and/or acids, acrylic polymers, polyvinyl alcohol, polyurethane dispersions, ethylene carbonate, propylene carbonate, lactones, lactams, lactides, acrylic based polymers with free carboxy groups and polyurethane dispersions with free carboxy groups.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation of U.S. application Ser. No. 17/916,461, filed on Sep. 30, 2025, which is a U.S. National Phase Application under 35 U.S.C. 371 of International Application No. PCT/EP2020/059619, filed on Apr. 3, 2020. The entire disclosures of the above applications are incorporated herein by reference. FIELD The present disclosure relates to a roofing system for a flat roof or a flat inclined roof of a building with a thermal and/or acoustic insulation, consisting of a structural support, a deck, optionally a vapour control layer, a waterproof membrane and at least one insulation element being a bonded mineral fibre product made of mineral fibres, preferably stone wool fibres, and a binder. Furthermore, the present disclosure relates to an Insulation element for such a roofing system, made of mineral fibres, preferably stone wool fibres, and a binder. BACKGROUND This section provides background information related to the present disclosure which is not necessarily prior art. Flat roofs and flat inclined roofs are well known in the prior art, e.g. as membrane roof systems which are generally divided into the following types, according to the position in which the principal thermal insulation is placed: warm roofs, inverted warm roofs, roof gardens or green roofs, and cold roofs. Membrane roof systems nowadays are often built as single ply roofing systems that are used to protect flat roofs or flat inclined roofs from all weather conditions likely to be experienced during their design life. A typical single ply roof system comprises: a structural support, a deck providing continuous support, a vapour control layer (if required), thermal insulation, a waterproof membrane and a traffic or load resistant finish (if required for functional and/or aesthetic reasons). Most flat roofs and flat inclined roofs these days are designed as so-called warm roofs. In such warm roofs the principal thermal insulation is placed immediately below the roof covering, namely the waterproof membrane. This keeps the deck warm during cold weather and manages condensation without the need for ventilation. A vapour control layer optionally is laid over the deck to control water vapour entering the insulation. This is a very reliable and cost-effective way to insulate a membrane roof to a high standard. The three principal options for attachment of single ply roofing systems are mechanical fastening, adhesion/cold gluing, ballast whereby the insulation and the membrane may be either attached by the same or a different method. Various systems described in the prior art are useful for roofing systems for flat or flat inclined roofs of buildings, and making use of insulation elements of bonded mineral fibre products. In certain instances it is also known to use layers of mineral fibres, for instance glass fibres, as a non-woven fleece or tissue across the insulation elements whereby it is sandwiched between the insulation elements and the waterproof membrane. A panel formed of several insulation elements arranged side-by-side may have a layer of non-woven fleece or tissue extending across its entire area. The fleece or tissue may be adhered to the element(s) by an adhesive applied between the contacting surfaces. The fleece or tissue holds the board's position in the panel and may improve the mechanical strength by enabling forces exerted on one element to be transferred to the adjacent element. The fleece or tissue has small pores, for instance having an average pore size or distance between adjacent fibres of less than 0.5 mm, for instance as little as 0.1 mm. State of the art roofing systems make use of tissue and fabric faced or bitumen coated roof boards to provide an adequate surface of the insulation element layer for the gluing/bonding of the waterproof membrane. These systems can be used but may however have the disadvantage that adhesives may disperse into the insulation element layer. Such dispersed adhesive significantly decreases the insulation and/or damping characteristics of said insulation layer. Moreover, dispersed adhesive will result in higher glue consumption and uncontrolled adhesion strength thus causing higher system costs. Finally, such adhesives which normally are organic adhesives reduce the fire resistance of the insulation elements, in particular in case of bitumen coated roof boards as they are mentioned above. For example, WO 98/31895 discloses a roofing system comprising a mineral fibre core, a fabric overlying the core and united to the core by a resin to form a panel and a moisture/water impermeable sheet overlying the fabric, which is joined to the panel by an adhesive which penetrates into the mineral fibre core. Although this composite roof system is widely used for flat and flat inclined roofs it has several disadvantages as described before. Another example of a roofing system is disclosed in WO 2013/034376. This roofing system comprises ins