US20060096205A1 - Roofing cover board, roofing panel composite, and method - Google Patents
Roofing cover board, roofing panel composite, and method Download PDFInfo
- Publication number
- US20060096205A1 US20060096205A1 US10/984,122 US98412204A US2006096205A1 US 20060096205 A1 US20060096205 A1 US 20060096205A1 US 98412204 A US98412204 A US 98412204A US 2006096205 A1 US2006096205 A1 US 2006096205A1
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- United States
- Prior art keywords
- density
- core layer
- low
- cover board
- major surface
- Prior art date
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- Abandoned
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Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
- E04D3/35—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation
- E04D3/351—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation at least one of the layers being composed of insulating material, e.g. fibre or foam material
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D12/00—Non-structural supports for roofing materials, e.g. battens, boards
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
- B29C44/22—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length consisting of at least two parts of chemically or physically different materials, e.g. having different densities
- B29C44/24—Making multilayered articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
- B29C44/32—Incorporating or moulding on preformed parts, e.g. linings, inserts or reinforcements
- B29C44/326—Joining the preformed parts, e.g. to make flat or profiled sandwich laminates
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D99/00—Subject matter not provided for in other groups of this subclass
- B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/42—Layered products comprising a layer of synthetic resin comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/022—Non-woven fabric
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/02—Physical, chemical or physicochemical properties
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
- E04C2/20—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
- E04C2/205—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics of foamed plastics, or of plastics and foamed plastics, optionally reinforced
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/296—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-material
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
- E04D3/02—Roof covering by making use of flat or curved slabs or stiff sheets of plane slabs, slates, or sheets, or in which the cross-section is unimportant
- E04D3/18—Roof covering by making use of flat or curved slabs or stiff sheets of plane slabs, slates, or sheets, or in which the cross-section is unimportant of specified materials, or of combinations of materials, not covered by any of groups E04D3/04, E04D3/06 or E04D3/16
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
- E04D3/35—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation
- E04D3/351—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation at least one of the layers being composed of insulating material, e.g. fibre or foam material
- E04D3/352—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation at least one of the layers being composed of insulating material, e.g. fibre or foam material at least one insulating layer being located between non-insulating layers, e.g. double skin slabs or sheets
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
- E04D3/35—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation
- E04D3/351—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation at least one of the layers being composed of insulating material, e.g. fibre or foam material
- E04D3/354—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation at least one of the layers being composed of insulating material, e.g. fibre or foam material more than one of the layers being composed of insulating material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B2038/0052—Other operations not otherwise provided for
- B32B2038/0084—Foaming
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/101—Glass fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/72—Density
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2419/00—Buildings or parts thereof
- B32B2419/06—Roofs, roof membranes
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
- Y10T428/24322—Composite web or sheet
- Y10T428/24331—Composite web or sheet including nonapertured component
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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- Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
- Y10T428/2495—Thickness [relative or absolute]
- Y10T428/24967—Absolute thicknesses specified
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T428/249978—Voids specified as micro
- Y10T428/24998—Composite has more than two layers
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T428/249987—With nonvoid component of specified composition
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract
A prefabricated cover board has a high-density polymer or predominantly polymer material core layer having a density between 6 lbs/ft3 and 25 lbs/ft3. A prefabricated roofing panel composite includes the cover board and an insulation board that has a low-density polymer or predominantly polymer material foam core layer having a density less than 6 lbs/ft3. The cover board may have a waterproofing membrane forming the top major surface of the cover board. When making the roofing panel composite, the low-density foam core layer of the insulation board may be formed with the high-density core layer of the cover board being currently or subsequently formed over and bonded to a top major surface of the low-density foam core layer in the same operation or preformed insulation boards may be fed into a production line with the high-density core layer of the cover board being formed over and bonded to top major surfaces of the low-density foam core layers of the insulation boards.
Description
- The subject invention relates to low-slope roofs that are typically found on commercial and industrial buildings and in particular to a prefabricated high-density polymer or predominantly polymer material cover board and a prefabricated roofing panel composite, which includes the high-density polymer or predominantly polymer material cover board and a low-density polymer or predominantly polymer material foam insulation board, for use on such low-slope roofs and to a method of making the cover board and the roofing panel composite
- Commercial and industrial buildings typically have roofs with low-slope roof decks. The roofing systems for these roofs with low-slope roof decks typically include one or more layers of a low-density roofing insulation, a layer of roofing cover boards that overlie the low-density roofing insulation layer(s), and a waterproofing membrane that overlies the layer of cover boards. The layer(s) of low-density insulation, such as a low-density polymer-based foam insulation, if not protected, can be partially crushed or otherwise damaged from worker traffic over the insulation, the placement of heaving objects on the insulation, the weather, and other causes commonly encountered in roofing construction. The layer of roofing cover boards that overlies the one or more layers of low-density insulation, protects the more fragile low density insulation from damage, acts as a fire barrier, provides a suitable substrate for the attachment of the overlying waterproofing membrane, and augments the insulating function of the low-density insulation. The uppermost waterproofing membrane layer overlying the cover board layer protects the underlying cover board and insulation layers from moisture and other adverse climatic conditions. Normally, these three components (the low-density insulation boards, the roofing cover boards, and the waterproofing membrane) of the roofing system are separately manufactured and separately and successively applied to the low-slope roof deck. While these roofing systems function very well, there has remained a need to provide an improved roofing cover board and to provide prefabricated roofing panel composites that combine at least an insulation board and the improved roofing cover board layer, and that, preferably, combine an insulation board, the improved roofing cover board layer and a waterproofing membrane. With the use of such an improved roofing cover board and prefabricated roofing panel composites, roofing systems for low-slope roof decks can be improved and/or the time, labor and costs associated with the installation of roofing systems on low-slope roof decks can be reduced. The subject invention provides an improved roofing cover board, an improved prefabricated roofing cover board and waterproofing membrane composite, an improved prefabricated roofing panel cover board and insulation board composite, and an improved prefabricated roofing panel cover board, insulation board, and waterproofing membrane composite. The subject invention also provides a method for making the improved roofing cover board and the prefabricated roofing panel composites including the improved roofing cover board that is highly productive, relatively economical, and efficient.
- The high-density polymer or predominantly polymer material cover board of the subject invention is or includes a high-density polymer or predominantly polymer material core layer with a density between 6 lbs/ft3 and 25 lbs/ft3. Preferably, a waterproofing membrane overlies and is bonded to the top major surface of the high-density core layer of the cover board to form a cover board and waterproofing membrane composite. When the cover board and waterproofing membrane composite is laid down and the waterproofing membrane is bonded and sealed to the waterproofing membranes of other cover board and waterproofing membrane composites, the waterproofing membrane protects the high-density core layer of the composite and underlying layers of the roofing system from moisture and other climatic conditions. A separate waterproofing membrane does not have to be applied over the cover board and waterproofing membrane composite at the job site to protect the high-density core layer of the cover board and underlying roofing system layers from moisture, UV radiation, and other climatic conditions. The density and thickness of the high-density polymer or predominantly polymer material core layer of the cover board are selected to provide the cover board with the compressive strength to resist deformation so that the cover board protects low-density insulation layers overlaid by the cover board from damage and so that the cover board has surface characteristics that promote the bonding of a top facer, e.g. waterproofing membrane, to the high-density core layer of the cover board. The prefabricated high-density polymer or predominantly polymer material cover board of the subject invention is relatively lightweight and easily cut. This makes the cover board easier to install and increases the productivity of workers installing the cover boards. In addition, the high-density polymer or predominantly polymer material cover board of the subject invention does not support mold growth, there are no glass fiber shards to cause skin and eye irritation for installers, and the cover board is not negatively impacted by the application of solvents, hot asphalt, or adhesives.
- The prefabricated roofing panel composites of the subject invention include the cover board with its high density polymer or predominantly polymer material core layer that has a density between 6 lbs/ft3 and 25 lbs/ft3 and a low-density insulation board with its low-density polymer or predominantly polymer material foam core layer that has a density less than 6 lbs/ft3. The bottom major surface of the high-density cover board overlies and is bonded to the top major surface of the low-density foam insulation board and, in a preferred embodiment, the high-density cover board includes a waterproofing membrane facer that overlies and is bonded to the top major surface of the high-density polymer or predominantly polymer material core of the cover board. The cover board and the roofing panel composite may be secured in a roofing system mechanically with screws, nails or other mechanical fasteners and/or adhesively with asphalt or other adhesives.
- When making the high-density polymer or predominantly polymer material cover board in accordance with the method of the subject invention, the high-density polymer or predominantly polymer material core layer of the cover board may be made without facers, with only a top waterproofing membrane facer, or with both a top waterproofing membrane facer and a bottom facer. When making the prefabricated roofing panel composites in accordance with the method of the subject invention, the low-density polymer or predominantly polymer material foam core layer of the low-density foam insulation board may be formed with the high-density core layer of the high-density cover board being concurrently or subsequently formed over and bonded to a top major surface of the low-density foam insulation board in the same operation. In an alternate version of the method of the subject invention for making the prefabricated roofing panel composite, preformed low-density foam insulation boards may be fed into a production line with the high-density polymer or predominantly polymer material core layer of the cover board being formed over and bonded to the top major surfaces of the preformed low-density foam insulation boards. In the method of the subject invention for making the prefabricated roofing panel composite, no facer or a common facer may be used intermediate the high-density core layer of the cover board and the low-density foam core layer of the foam insulation board. In addition, a waterproofing membrane facer may be applied and bonded to the top major surface of the high-density polymer or predominantly polymer material core layer of the cover board.
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FIG. 1 is a schematic perspective view of a prefabricated high-density polymer or predominantly polymer material cover board of the subject invention. -
FIG. 2 is a schematic perspective view of a composite of the subject invention that includes a prefabricated high-density polymer or predominantly polymer material cover board and a top facer. -
FIG. 3 is a schematic perspective view of a prefabricated roofing panel composite of the subject invention that includes a high-density polymer or predominantly polymer material cover board and a low-density polymer or predominantly polymer material foam insulation board. -
FIG. 4 is a schematic perspective view of a prefabricated roofing panel composite of the subject invention that includes a high-density polymer or predominantly polymer material cover board, a low-density polymer or predominantly polymer material foam insulation board, and a top facer. -
FIG. 5 is a schematic perspective view of a prefabricated roofing panel composite of the subject invention that includes a high-density polymer or predominantly polymer material cover board, a low-density polymer or predominantly polymer material foam insulation board, and a high-density polymer or predominantly polymer material baseboard. -
FIG. 6 is a schematic perspective view of a prefabricated roofing panel composite of the subject invention that includes a high-density polymer or predominantly polymer material cover board, a low-density polymer or predominantly polymer material foam insulation board, a high-density polymer or predominantly polymer material baseboard, and a top facer. -
FIG. 7 is a schematic side view of a first production line that can be used with the method of the subject invention to make a prefabricated roofing panel composite of the subject invention that includes a high-density polymer or predominantly polymer material cover board and a low-density polymer or predominantly polymer material foam insulation board. -
FIG. 8 is a schematic side view of a second production line that can be used with the method of the subject invention to make a prefabricated roofing panel composite of the subject invention that includes a high-density polymer or predominantly polymer material cover board and a low-density polymer or predominantly polymer material foam insulation board. -
FIG. 9 is a schematic side view of a production line that can be used with the method of the subject invention to make a prefabricated roofing panel composite of the subject invention that includes a high-density polymer or predominantly polymer material cover board, a low-density polymer or predominantly polymer material foam insulation board, and a high-density polymer or predominantly polymer material baseboard. -
FIG. 10 is a schematic side view of a third production line that can be used with the method of the subject invention to make a prefabricated roofing panel composite of the subject invention that includes a high-density polymer or predominantly polymer material cover board and a low-density polymer or predominantly polymer material foam insulation board. -
FIG. 1 is a schematic perspective view of thecover board 10 of the subject invention, which has a high-density polymer or predominantly polymermaterial core layer 12. The high-density polymer or predominantly polymermaterial core layer 12 of thecover board 10 has a density between 6 lbs/ft3 and 25 lbs/ft3 and preferably a density of at least 8 lbs/ft3. The high-density polymer or predominantly polymermaterial core layer 12 of thecover board 10 has a thickness of about 0.08 inches or greater and, preferably, a thickness between about 0.08 inches and about 0.75 inches. The density and thickness of the high-density polymer or predominantly polymermaterial core layer 12 of thecover board 10 are selected to provide the cover board with the compressive strength to resist deformation and protect low-density insulation layers overlaid by the cover board from damage, and to provide surface characteristics that promote the bonding of a top facer, e.g. a waterproofing membrane, to the high-density core layer of the cover board. - The high-density polymer or predominantly polymer
material core layer 12 has a topmajor surface 14 and a bottom major surface 16 that are each defined by the length and the width of the high-density polymer or predominantly polymer material core layer. The high-density polymer or predominantly polymermaterial core layer 12 typically has a width of about four feet or greater and a length of about four feet or greater, preferably, about eight feet or greater and could have lengths that are limited only by the ability to store, transport, and handle the high-density polymer or predominantly polymermaterial cover board 10 prior to installation. - The
cover board 10 may have top and/or bottom facers that are not shown inFIG. 1 . When used, the top and/or bottom facers typically overlie the entire or substantially the entiremajor surface 14 and/or 16 of the high-density polymer or predominantly polymermaterial core layer 12 to which the facers are bonded. The top and bottom facers of the high-density polymer or predominantly polymermaterial cover board 10 may be any sheet material that provides suitable top and bottom major surfaces for the cover board, such as but not limited to paper, foil, woven or nonwoven mats made of fiberglass or other fibers or filaments, scrims, etc. - The high-density polymer or predominantly polymer
material core layer 12 of thecover board 10 may be made of various high-density polymer or predominantly polymer materials [e.g. a high-density polyisocyanurate, polyurethane, polystyrene, or phenolic material or a high-density material made of a blend of these materials; a high-density polyisocyanurate, polyurethane, polystyrene, or phenolic foam material or a high-density foam material made of a blend of these materials; a high-density predominantly polyisocyanurate, polyurethane, polystyrene, or phenolic material with inorganic filler(s) or a high-density material made of a blend of these materials with filler(s); a high-density predominantly polyisocyanurate, polyurethane, polystyrene, or phenolic foam material with inorganic filler(s) or a high-density foam material made of a blend of these materials with filler(s), a high-density material made of other thermoset matrix polymers; etc.]. However, a preferred material for the high-density core layer 12 is a high-density polyisocyanurate or predominantly polyisocyanurate material or foam material. The predominantly polymer materials of the high-density core layer 12 may contain various powdered and liquid fillers, fiber reinforcements, fungi growth-inhibiting agents, and fire-retardants to reduce the cost of and/or modify the properties of the high-density core layer 12, such as but not limited to the compressive strength, the toughness, the flexibility, the friability, and the fire resistance of the core layer. Examples of fillers that may be used in the high-density predominantly polymermaterial core layer 12 are fillers such as limestone (CaCO3), fiberglass, recycled polyisocyanurate dust, and extenders/plasticizers. -
FIG. 2 is a schematic perspective view of a prefabricated cover board and facercomposite 20 of the subject invention. Thecomposite 20 includes thecover board 10 and afacer 22, e.g. a waterproofing membrane. Other than the inclusion of atop facer 22, the prefabricated cover board and facercomposite 20 is the same as thecover board 10 ofFIG. 1 . - The
top facer 22 of thecomposite 20 may be any sheet material that provides a suitable top major surface for the cover board and facer composite, such as but not limited to paper, foil, woven or nonwoven mats made of fiberglass or other fibers or filaments, scrims, etc. However, a preferred sheet material for thetop facer 22 is a sheet material that serves the dual function of providing a facing during the manufacturing process and a waterproofing membrane on the finished product such as but not limited to a bituminous or modified bituminous membrane, or a single ply membrane (e.g. a EPDM, PVC, or TPO membrane). Where thetop facer 22 is a waterproofing membrane, the facer may extend beyond the high-density polymer or predominantly polymer material core layer of thecover board 10 on one or more of the four sides of the core layer (e.g. beyond a side edge and an end edge of the top major surface of the core layer) to form membrane overlaps for sealing to the membranes ofother composites 20. While not shown, the composite may also include a bottom facer that is bonded to the bottom major surface of the high-density polymer or predominantly polymer material core layer of the cover board. When used, the bottom facer of thecomposite 20 may be any sheet material that provides a suitable bottom major surface for the cover board and facer composite for bonding to an underlying layer of the roofing system, such as but not limited to paper, woven or nonwoven mats made of fiberglass or other fibers or filaments, scrims, etc. -
FIG. 3 is a schematic perspective view of a first prefabricatedroofing panel composite 30 of the subject invention. The prefabricatedroofing panel composite 30 includes a high-density polymer or predominantly polymermaterial cover board 32 and aninsulation board 34 that, as shown, are bonded directly together. The prefabricatedroofing panel composite 30 has a topmajor surface 36 and a bottommajor surface 38 that are each defined by the length and the width of the roofing panel composite. The prefabricatedroofing panel composite 30 typically has a width of about four feet or greater and a length of about four feet or greater, preferably, about eight feet or greater and could have lengths that are limited only by the ability to store, transport and handle the roofing panel composites prior to installation. - In the prefabricated
roofing panel composite 30, thecover board 32 has a high-density polymer or predominantly polymermaterial core layer 40. The high-density polymer or predominantly polymermaterial core layer 40 of thecover board 32 in the prefabricatedroofing panel composite 30 has a density between 6 lbs/ft3 and 25 lbs/ft3 and preferably a density of at least 8 lbs/ft3. The high-density polymer or predominantly polymermaterial core layer 40 of thecover board 32 in the prefabricated roofing panel composite has a thickness of about 0.08 inches or greater and, preferably, a thickness between about 0.08 inches and about 0.75 inches. The density and thickness of the high-density polymer or predominantly polymermaterial core layer 40 of thecover board 32 are selected to provide the cover board with the compressive strength to resist deformation and protect the low-density insulation board 34 that is overlaid by the cover board from damage, and to provide surface characteristics that promote the bonding of a top facer, e.g. a waterproofing membrane, to the high-density core layer 40 of the cover board. - The
insulation board 34 in the prefabricatedroofing panel composite 30 includes a low-density polymer or predominantly polymer materialfoam core layer 42. The low-density polymer or predominantly polymer materialfoam core layer 42 of theinsulation board 34 has a density less than 6 lbs/ft3, preferably less than 4 lbs/ft3, and typically a density between about 1 lbs/ft3 and about 3 lbs/ft3. The low-density polymer or predominantly polymer materialfoam core layer 42 has a thickness of about 0.50 inches or greater and, preferably, a thickness between about 0.50 inches and about 6 inches. The density and thickness of the low-density polymer or predominantly polymer materialfoam core layer 42 of theinsulation board 34 are selected to provide the prefabricatedroofing panel composite 30 with the desired insulating properties for the roofing system application. - The high-density polymer or predominantly polymer
material core layer 40 of thecover board 32 may be made of various high-density polymer or predominantly polymer materials [e.g. a high-density polyisocyanurate, polyurethane, polystyrene, or phenolic material or a high-density material made of a blend of these materials; a high-density polyisocyanurate, polyurethane, polystyrene, or phenolic foam material or a high-density foam material made of a blend of these materials; a high-density predominantly polyisocyanurate, polyurethane, polystyrene, or phenolic material with inorganic filler(s) or a high-density material made of a blend of these materials with filler(s); a high-density predominantly polyisocyanurate, polyurethane, polystyrene, or phenolic foam material with inorganic filler(s) or a high-density foam material made of a blend of these materials with filler(s), a high-density material made of other thermoset matrix polymers; etc.]. However, a preferred material for the high-density core layer 40 is a high-density polyisocyanurate or predominantly polyisocyanurate material or foam material. - The low-density polymer or predominantly polymer material
foam core layer 42 of theinsulation board 34 may be made of various low-density polymer or predominantly polymer foam materials [e.g. a low-density polyisocyanurate, polyurethane, polystyrene, or phenolic foam material or a low-density foam material made of a blend of these materials; a low-density predominantly polyisocyanurate, polyurethane, polystyrene, or phenolic foam material with inorganic filler(s) or a low-density foam material made of a blend of these materials with filler(s), a low-density foam material made of other thermoset matrix polymers; etc.]. However, a preferred material for the low-density core layer 42 is a low-density polyisocyanurate or predominantly polyisocyanurate foam material. - When the high-
density core layer 40 is made of a predominantly polymer material, the high-density predominantly polymer material of thecore layer 40 may contain various powdered and liquid fillers, fiber reinforcements, fire-retardants, fungi growth-inhibiting agents, etc. to reduce the cost and/or modify the properties of the high-density core layer 40 (such as but not limited to the compressive strength, the flexibility, the friability, the fire resistance of the core layer). When the low-density core layer 42 is made of a predominantly polymer material foam, the low-density predominantly polymer materialfoam core layer 42 may contain various powdered and liquid fillers fiber reinforcements, fire-retardants, fungi growth-inhibiting agents, etc. to reduce the cost and/or modify the properties of the low-density predominantly polymer material foam core layer. Examples of fillers that may be used in the high-density core layer 40 of thecover board 32 and the low-density core layer 42 of theinsulation board 34 are fillers such as limestone (CaCO3), fiberglass, recycled polyisocyanurate dust, and extenders/plasticizers. - While, as shown in
FIG. 3 , the prefabricatedroofing panel composite 30 has no facers, the prefabricatedroofing panel composite 30 could have a common facer intermediate and bonded to both the bottom major surface of the coverboard core layer 40 and the top major surface of the insulationboard core layer 42, a top facer bonded to the top major surface of the coverboard core layer 40, and/or a bottom facer bonded to the bottom major surface of the insulationboard core layer 42. When used, the common facer of the prefabricatedroofing panel composite 30 may be any sheet material with good bonding surfaces that facilitates a good bond between thecover board 32 andinsulation board 34, such as but not limited to woven or nonwoven mats made of glass fibers, other fibers or filaments, scrims, etc. When used, the top facer of the prefabricatedroofing panel composite 30 overlies the entire or substantially the entire top major surface of the high-density core layer 40 of thecover board 32. The top facer of the prefabricatedroofing panel composite 30 may be any sheet material that provides a suitable top major surface for the prefabricatedroofing panel composite 30, such as but not limited to paper, foil, woven or nonwoven mats made of fiberglass or other fibers or filaments, scrims, etc. When used, the bottom facer of the prefabricatedroofing panel composite 30 overlies the entire or substantially the entire bottom surface of the low-densityfoam core layer 42 of theinsulation board 34. The bottom facer of the prefabricatedroofing panel composite 30 may be any sheet material that provides a suitable bottom major surface for theroofing panel composite 30, such as but not limited to paper, foil, woven or nonwoven mats made of fiberglass or other fibers or filaments, scrims, etc. -
FIG. 4 is a schematic perspective view of a prefabricatedroofing panel composite 50 of the subject invention. The prefabricatedroofing panel composite 50 includes the high-density polymer or predominantly polymermaterial cover board 32 and the low-density polymer or predominantly polymer materialfoam insulation board 34 that, as shown inFIG. 4 , are bonded directly together, and atop facer 52. Other than the inclusion of thetop facer 52, the prefabricatedroofing panel composite 50 is the same as the prefabricatedroofing panel composite 30 ofFIG. 3 . - The
top facer 52 of the prefabricatedroofing panel composite 50 is bonded to and overlies the entire or substantially the entire top surface of the high-density polymer or predominantly polymer material core layer of thecover board 32. Thetop facer 52 of the prefabricatedroofing panel composite 50 may be any sheet material that provides a suitable top major surface for the cover board and facer composite, such as but not limited to paper, foil, woven or nonwoven mats made of fiberglass or other fibers or filaments, scrims, etc. However, a preferred sheet material for thetop facer 52 is a sheet material that serves the dual function of providing a facing during the manufacturing process and a waterproofing membrane on the finished product such as but not limited to a bituminous or modified bituminous membrane, or a single ply membrane (e.g. a EPDM, PVC, or TPO membrane). Where thetop facer 52 is a waterproofing membrane, the facer may extend beyond the high-density core layer of thecover board 32 on one or more of the four sides of the core layer, e.g. beyond a side edge and an end edge of the top major surface of the core layer to provide overlaps for sealing with the membranes of adjacent panels. - While, as shown in
FIG. 4 , the prefabricatedroofing panel composite 50 only has atop facer 52, the prefabricatedroofing panel composite 50 could have a common facer intermediate and bonded to both the bottom major surface of thecover board 32core layer 40 and the top major surface of theinsulation board 34core layer 42, and/or a bottom facer bonded to the bottom major surface of theinsulation board 34core layer 42. When used, the common facer of the prefabricatedroofing panel composite 50 may be any sheet material with good bonding surfaces that facilitates a good bond between thecover board 32 andinsulation board 34, such as but not limited to woven or nonwoven mats made of glass fibers, other fibers or filaments, scrims, etc. When used, the bottom facer of the prefabricatedroofing panel composite 50 overlies the entire or substantially the entire bottom surface of the low-density foam core layer of theinsulation board 34. The bottom facer of the prefabricatedroofing panel composite 50 may be any sheet material that provides a suitable bottom major surface for theroofing panel composite 50, such as but not limited to paper, foil, woven or nonwoven mats made of fiberglass or other fibers or filaments, scrims, etc. -
FIG. 5 is a schematic perspective view of a prefabricatedroofing panel composite 60 of the subject invention that includes: a high-density polymer or predominantly polymermaterial cover board 62, a low-density polymer or predominantly polymer materialfoam insulation board 64, and a high-density polymer or predominantlypolymer material baseboard 66. The high-density polymer or predominantly polymermaterial cover board 62 andbaseboard 66 may have the same density or different densities. As shown inFIG. 5 , thecover board 62, theinsulation board 64, and thebaseboard 66 are bonded directly together. The prefabricatedroofing panel composite 60 has a topmajor surface 68 and a bottommajor surface 70 that are each defined by the length and the width of the prefabricated roofing panel composite. The prefabricatedroofing panel composite 60 typically has a width of about four feet or greater and a length of about four feet or greater, preferably, about eight feet or greater and could have lengths that are limited only by the ability to store, transport and handle the roofing panel composites prior to installation. - In the prefabricated
roofing panel composite 60, thecover board 62 has a high-density polymer or predominantly polymermaterial core layer 72 and thebaseboard 66 has a high-density polymer or predominantly polymermaterial core layer 74. The high-density polymer or predominantly polymer material core layers 72 and 74 each have a density between 6 lbs/ft3 and 25 lbs/ft3 and preferably a density of at least 8 lbs/ft3. The high-density polymer or predominantly polymermaterial core layer 72 of thecover board 62 and the high-density polymer or predominantly polymermaterial core layer 74 of thebaseboard 66 each have a thickness of about 0.08 inches or greater and, preferably, a thickness between about 0.08 inches and about 0.75 inches. The density and thickness of the high-density polymer or predominantly polymermaterial core layer 72 of thecover board 62 are selected to provide the cover board with the compressive strength to resist deformation and protect the low-density insulation board 64 that is overlaid by the cover board from damage, and to provide surface characteristics that promote the bonding of a top facer, e.g. a waterproofing membrane, to thecore layer 72 of the cover board. - The
insulation board 64 in the prefabricatedroofing panel composite 60 includes a low-density polymer or predominantly polymerfoam core layer 76. The low-density polymer or predominantly polymer materialfoam core layer 76 of theinsulation board 64 has a density less than 6 lbs/ft3, preferably less than 4 lbs/ft3, and typically a density between about 1 lbs/ft3 and about 3 lbs/ft3. The low-density polymer or predominantly polymer materialfoam core layer 76 has a thickness of about 0.50 inches or greater and, preferably, a thickness between about 0.50 inches and about 6 inches. The density and thickness of the low-density polymer or predominantly polymer materialfoam core layer 76 of theinsulation board 64 are selected to provide the prefabricatedroofing panel composite 60 with the desired insulating properties for the roofing system application. - The high-density polymer or predominantly polymer material core layers 72 and 74 of the
cover board 62 and thebaseboard 66 may be made of various high-density polymer or predominantly polymer materials [e.g. a high-density polyisocyanurate, polyurethane, polystyrene, or phenolic material or a high-density material made of a blend of these materials; a high-density polyisocyanurate, polyurethane, polystyrene, or phenolic foam material or a high-density foam material made of a blend of these materials; a high-density predominantly polyisocyanurate, polyurethane, polystyrene, or phenolic material with inorganic filler(s) or a high-density material made of a blend of these materials with filler(s); a high-density predominantly polyisocyanurate, polyurethane, polystyrene, or phenolic foam material with inorganic filler(s) or a high-density foam material made of a blend of these materials with filler(s), a high-density material made of other thermoset matrix polymers; etc.]. However, a preferred material for the high-density core layers 72 and 74 is a high-density polyisocyanurate or predominantly polyisocyanurate material or foam material. - The low-density polymer or predominantly polymer material
foam core layer 76 of theinsulation board 64 may be made of various low-density polymer or predominantly polymer foam materials [e.g. a low-density polyisocyanurate, polyurethane, polystyrene, or phenolic foam material or a low-density foam material made of a blend of these materials; a low-density predominantly polyisocyanurate, polyurethane, polystyrene, or phenolic foam material with inorganic filler(s) or a low-density foam material made of a blend of these materials with filler(s), a low-density material made of other thermoset matrix polymers; etc.]. However, a preferred material for the low-density core layer 76 is a low-density polyisocyanurate or predominantly polyisocyanurate foam material. - When the high-density core layers 72 and 74 are made of a predominantly polymer material, the high-density predominantly polymer material of the core layers 72 and 74 may contain various powdered and liquid fillers, fiber reinforcements, fire-retardants, fungi growth-inhibiting agents, etc. to reduce the cost and/or modify the properties of the high-density core layers 72 and 74 (such as but not limited to the compressive strength, the flexibility, the friability, the fire resistance of the core layer). When the low-
density core layer 76 is made of a predominantly polymer material foam, the low-density predominantly polymer materialfoam core layer 76 may contain various powdered and liquid fillers fiber reinforcements, fire-retardants, fungi growth-inhibiting agents, etc. to reduce the cost and/or modify the properties of the low-density foam core layer. Examples of fillers that may be used in the high-density core layers 72 of thecover board 62 and thebaseboard 66 and the low-density core layer 76 of theinsulation board 64 are fillers such as limestone (CaCO3), fiberglass, recycled polyisocyanurate dust, and extenders/plasticizers. - While, as shown in
FIG. 5 , the prefabricatedroofing panel composite 60 has no facers, the prefabricatedroofing panel composite 60 could have a common facer intermediate and bonded to both the bottom major surface of the coverboard core layer 72 and the top major surface of the insulationboard core layer 76, a common facer intermediate and bonded to both the bottom major surface of the insulationboard core layer 76 and the top major surface of thebaseboard core layer 74, a top facer bonded to the top major surface of the coverboard core layer 72, and/or a bottom facer bonded to the bottom major surface of thebaseboard core layer 74. When used, the common facers of the prefabricatedroofing panel composite 60 may be any sheet material with good bonding surfaces that facilitates a good bond between thecover board 62, theinsulation board 64, and thebaseboard 66, such as but not limited to woven or nonwoven mats made of glass fibers, other fibers or filaments, scrims, etc. When used, the top facer of the prefabricatedroofing panel composite 60 overlies the entire or substantially the entire top major surface of the high-density core layer 72 of thecover board 62. The top facer of the prefabricatedroofing panel composite 60 may be any sheet material that provides a suitable top major surface for the prefabricatedroofing panel composite 60, such as but not limited to paper, foil, woven or nonwoven mats made of fiberglass or other fibers or filaments, scrims, etc. When used, the bottom facer of the prefabricatedroofing panel composite 60 overlies the entire or substantially the entire bottom surface of the high-density core layer 74 of thebaseboard 66. The bottom facer of the prefabricatedroofing panel composite 60 may be any sheet material that provides a suitable bottom major surface for theroofing panel composite 60, such as but not limited to paper, foil, woven or nonwoven mats made of fiberglass or other fibers or filaments, scrims, etc. -
FIG. 6 is a schematic perspective view of a prefabricatedroofing panel composite 80 of the subject invention. The prefabricatedroofing panel composite 80 includes the high-density polymer or predominantly polymermaterial cover board 62, the low-density polymer or predominantly polymer materialfoam insulation board 64, and the high-density polymer or predominantlypolymer material baseboard 66, that, as shown inFIG. 6 , are bonded directly together, and atop facer 82. Other than the inclusion of atop facer 82, the prefabricatedroofing panel composite 80 ofFIG. 6 is the same as the prefabricatedroofing panel composite 60 ofFIG. 5 . - The
top facer 82 of the prefabricatedroofing panel composite 80 is bonded to and overlies the entire or substantially the entire top surface of the high-density polymer or predominantly polymer material core layer of thecover board 62. Thetop facer 82 of the prefabricatedroofing panel composite 80 may be any sheet material that provides a suitable top major surface for the cover board and facer composite, such as but not limited to paper, foil, woven or nonwoven mats made of fiberglass or other fibers or filaments, scrims, etc. However, a preferred sheet material for thetop facer 82 is a sheet material that serves the dual function of providing a facing during the manufacturing process and a waterproofing membrane on the finished product such as but not limited to a bituminous or modified bituminous membrane, or a single ply membrane (e.g. a EPDM, PVC, or TPO membrane). Where thetop facer 82 is a waterproofing membrane, the facer may extend beyond the high-density polymer or predominantly polymer material core layer of thecover board 62 on one or more of the four sides of the core layer, e.g. beyond a side edge and an end edge of the top major surface of the core layer to provide membrane overlaps for sealing with the membranes of adjacent panels. - While, as shown in
FIG. 6 , the prefabricatedroofing panel composite 80 only has atop facer 82, the prefabricatedroofing panel composite 80 could have a common facer intermediate and bonded to both the bottom major surface of the cover board core layer and the top major surface of the insulation board core layer, a common facer intermediate and-bonded to both the bottom major surface of the insulation board core layer and the top major surface of the baseboard core layer, and/or a bottom facer bonded to the bottom major surface of the baseboard core layer. When used, the common facers of the prefabricatedroofing panel composite 80 may be any sheet material with good bonding surfaces that facilitates a good bond between the cover board and insulation board and the insulation board and the baseboard, such as but not limited to woven or nonwoven mats made of glass fibers, other fibers or filaments, scrims, etc. When used, the bottom facer of the prefabricatedroofing panel composite 80 overlies the entire or substantially the entire bottom surface of the high-density core layer of thebaseboard 66. The bottom facer of the prefabricatedroofing panel composite 80 may be any sheet material that provides a suitable bottom major surface for the prefabricatedroofing panel composite 80, such as but not limited to paper, foil, woven or nonwoven mats made of fiberglass or other fibers or filaments, scrims, etc. -
FIG. 7 is a schematic side view of afirst production line 100 that can be used with the method of the subject invention to continuously make prefabricated roofing panel composites of the subject invention in line, such as the prefabricatedroofing panel composites 30 ofFIG. 3 and 50 ofFIG. 4 . The prefabricatedroofing panel composites material cover board 32 and a low-density polymer or predominantly polymer materialfoam insulation board 34. Theproduction line 100 includes: a first formingstation 102 for forming the low-density polymer or predominantly polymer materialfoam insulation board 34 of the prefabricatedroofing panel composites station 104 for forming the high-density polymer or predominantly polymermaterial cover board 32 of the prefabricatedroofing panel composites station 106 for cutting the prefabricatedroofing panel composites - The first forming
station 102 for forming the low-densityfoam insulation board 34 includes a conventional dispenser 108 for dispensing a low-density polymer or predominantly polymer material foam precursor 110 (e.g. a low-density polyisocyanurate or predominantly polyisocyanurate foam precursor) onto a facer, when used, overlying aconveyor 112 of two spaced-apart opposed formingconveyers conveyor 112. As thefoam precursor 110 passes between the formingconveyors conveyors foam core layer 42 of the low-density polymer or predominantly polymerfoam insulation board 34 formed from theprecursor 110. The first formingstation 102 also includes supplies (e.g. rolls) offacer materials material foam precursor 110 to form a common facer of the prefabricatedroofing panel composites roofing panel composites - The second forming
station 104 of theproduction line 100 for forming the high-density polymer or predominantly polymermaterial cover board 32 of the prefabricatedroofing panel composites foam core layer 42 or, when used, a common facer overlying the low-density polymer or predominantly polymer materialfoam core layer 42. With the high-density polymer or predominantlypolymer material precursor 122 overlying the low-densityfoam core layer 42 or, when used, the common facer, the high-density polymer or predominantlypolymer material precursor 122 and the low-densityfoam core layer 42 pass between two spaced-apart opposed formingconveyers material core layer 38 is formed and bonded directly to the low-densityfoam core layer 42 or to the common facer overlying the low-densityfoam core layer 42. The spaced-apart opposed formingconveyors material core layer 40 and the prefabricatedroofing panel composite station 104 also includes supplies (e.g. rolls) of afacer material 126 that is fed over the high-density polymer or predominantlypolymer material precursor 122 to form thetop facer 52 of both the high-density cover board 32 and the prefabricatedroofing panel composite 50. - With the high-
density core layer 40 and the low-densityfoam core layer 42 of the prefabricatedroofing panel composite station 104 to form a continuous length of the prefabricatedroofing panel composite roofing panel composite roofing panel composite reciprocating cutter 128, cuts the prefabricatedroofing panel composite station 104 to length. - While the
production line 100, as shown, is capable of applying threefacer materials insulation board 34 and thecover board 32 to form the prefabricatedroofing panel composites materials roofing panel composite 30 and all but the top facing material can be omitted to form the prefabricatedroofing panel composite 50 with the desired number of facers. Thefacers precursors -
FIG. 8 is a schematic side view of asecond production line 200 that can be used with the method of the subject invention to continuously make prefabricated roofing panel composites of the subject invention, such as the prefabricatedroofing panel composites 30 ofFIG. 3 and 50 ofFIG. 4 . The prefabricatedroofing panel composites production line 200 includes: an in-feed conveyor 202 for continuously feeding a series of low-density polymer or predominantly polymer materialfoam insulation boards 34 of the prefabricated roofing panel composite into a formingstation 204; the formingstation 204 for forming the high-density polymer or predominantly polymermaterial cover board 32 of the prefabricatedroofing panel composites station 206 for cutting the prefabricatedroofing panel composites - The low-density polymer or predominantly polymer material
foam insulation boards 34 may include a top facer that, when used, forms a common facer of the prefabricatedroofing panel composites foam insulation boards 34 are fed into the formingstation 204 lengthwise with the ends ofsuccessive insulation boards 34 in the continuous series of insulation boards abutting each other. - The forming
station 204 of theproduction line 200 for forming the high-density polymer or predominantly polymermaterial cover board 32 of the prefabricatedroofing panel composite 30 includes aconventional dispenser 208 for dispensing the high-density polymer or predominantly polymer material precursor 210 (e.g. a high-density polyisocyanurate or predominantly polyisocyanurate precursor) directly onto the low-density foam core layers 42 of theinsulation boards 34 or, when used the common facers overlying the low-density foam core layers of the low-density foam insulation boards. With the high-density polymer or predominantlypolymer material precursor 210 directly overlying the low-density foam core layers 42 of the insulation boards or thecommon facers 36 carried by the low-densityfoam insulation boards 34, the high-density polymer or predominantlypolymer material precursor 210 and the low-densityfoam insulation boards 34 pass between two spaced-apart opposed formingconveyers cover boards 32 are formed and bonded directly to the low-density foam core layers 42 of theinsulation boards 34 or to the common facers overlying the low-densityfoam insulation board 34. The spaced-apart opposed formingconveyors material core layer 40 and the prefabricatedroofing panel composite station 204 also includes supplies (e.g. rolls) of afacer material 216 that is fed over the high-density polymer or predominantlypolymer material precursor 210 to form thetop facer 52 of both the high-density polymer or predominantly polymermaterial cover board 32 and the prefabricatedroofing panel composite 50. - With the high-
density core layer 40 and the low-densityfoam core layer 42 of the prefabricatedroofing panel composite station 204 to form a continuous length of the prefabricatedroofing panel composite roofing panel composite roofing panel composite roofing panel composite 30 coming from the formingstation 204 to length. - The
production line 200, as shown, is capable of making the prefabricatedroofing panel composite 30 by feeding preformed low-density polymer or predominantly polymer materialfoam insulation boards 34 into the formingstation 204 and omitting the application of thefacer material 216 to thecover board 32 and is capable of making the prefabricatedroofing panel composite 50 by feeding preformed low-density polymer or predominantly polymer materialfoam insulation boards 34 into the formingstation 204 and applying of thefacer material 216 to thecover board 32. Thefacer 216 normally prevents the high-density polymer or predominantly polymer material layer from sticking to theconveyor 212. However, with a shift in the chemistry of theprecursor 210 to affect the tackiness of the layer produced so that the layer does not stick to the surface of theconveyor 212 or by applying a release film or coating to the surface of theconveyer 212 that will not allow the layer produced to stick to the surface of the conveyor, when desired, the facingmaterials 216 is not needed for and could be eliminated from the manufacturing process. -
FIG. 9 is a schematic side view of aproduction line 300 that can be used with the method of the subject invention to continuously make a prefabricated roofing panel composite of the subject invention, such as the prefabricatedroofing panel composites 60 ofFIG. 5 and 80 ofFIG. 6 . These prefabricated roofing panel composites each include: a high-density polymer or predominantly polymermaterial cover board 62, a low-density polymer or predominantly polymer materialfoam insulation board 64, and a high-density polymer or predominantlypolymer material baseboard 66. Theproduction line 300 includes: a first formingstation 302 for forming the high-density polymer or predominantlypolymer material baseboard 66 of the prefabricatedroofing panel composites station 304 for forming the low-density polymer or predominantly polymer materialfoam insulation board 64 of the prefabricatedroofing panel composites station 306 for forming the high-density polymer or predominantly polymermaterial cover board 62 of the prefabricatedroofing panel composites station 308 for cutting the prefabricatedroofing panel composites - The first forming
station 302 for forming the high-density polymer or predominantly polymer material baseboard 56 includes aconventional dispenser 310 for dispensing a high-density polymer or predominantly polymer material precursor 312 (e.g. a high-density polyisocyanurate or predominantly polyisocyanurate precursor) onto a facer, when used, overlying a conveyor 314 of two spaced-apart opposed formingconveyers 314 and 316 or directly onto the conveyor 314. As theprecursor 310 passes between the formingconveyors 314 and 316, forms and at least partially sets, the formingconveyors 314 and 316 cooperate to set the thickness of the high-density polymer or predominantly polymermaterial core layer 74 of the high-density baseboard 66 formed from theprecursor 310. The first formingstation 302 also includes supplies (e.g. rolls) offacer materials 318 and 320 that may be fed over and/or beneath the high-density polymer or predominantlypolymer material precursor 310 to form, when used, a common facer of the prefabricatedroofing panel composites roofing panel composites - The second forming
station 304 of theproduction line 300 for forming the low-density polymer or predominantly polymer materialfoam insulation board 64 of the prefabricatedroofing panel composites conventional dispenser 322 for dispensing a low-density polymer or predominantly polymer material foam precursor 324 (e.g. a low-density polyisocyanurate or predominantly polyisocyanurate foam precursor) directly onto the high-density core layer 74 or, when used, onto a common facer overlying the high-density core layer 74 of thebaseboard 66. With the low-density polymer or predominantly polymermaterial foam precursor 324 directly overlying high-density core layer 74 or the common facer overlying the high-density core layer 74 of thebaseboard 66, the low-density polymer or predominantly polymermaterial foam precursor 324 and the high-density core layer 74 pass between two spaced-apart opposed formingconveyers 314 and 326 where the low-density polymer or predominantly polymer materialfoam core layer 76 of theinsulation board 64 is formed and bonded to the high-density core layer 74 or the common facer overlying the high-density core layer 74 of thebaseboard 66. The spaced-apart opposed formingconveyors 314 and 326 cooperate to set the thickness of the low-density polymer or predominantly polymer materialfoam core layer 76 of theinsulation board 64. The second formingstation 304 also includes supplies (e.g. rolls) of afacer material 328 that can be fed over the low-density polymer or predominantly polymermaterial foam precursor 324 to form a common facer of the prefabricatedroofing panel composites - The third forming
station 306 of theproduction line 300 for forming the high-density polymer or predominantly polymermaterial cover board 62 of the prefabricatedroofing panel composites conventional dispenser 330 for dispensing a high-density polymer or predominantly polymer material precursor 332 (e.g. a high-density polyisocyanurate or predominantly polyisocyanurate precursor) directly onto the low-densityfoam core layer 76 or the common facer overlying the low-densityfoam core layer 76 of theinsulation board 64. With the high-density polymer or predominantlypolymer material precursor 332 overlying the low-densityfoam core layer 76 or the common facer overlying the low-densityfoam core layer 76, the high-density polymer or predominantlypolymer material precursor 332, the low-densityfoam insulation board 64, and the high-density baseboard 66 pass between two spaced-apart opposed formingconveyers 314 and 334 where the high-density polymer or predominantly polymermaterial core layer 72 of thecover board 62 is formed and bonded to the low-densityfoam core layer 76 or the common facer overlying the low-densityfoam core layer 76 of theinsulation board 64. The spaced-apart opposed formingconveyors 314 and 334 cooperate to set the thickness of both the high-density polymer or predominantly polymermaterial core layer 72 and the prefabricatedroofing panel composite station 306 also includes supplies (e.g. rolls) of afacer material 336 that is fed over the high-density polymer or predominantlypolymer material precursor 332 to form thetop facer 82 of both the high-density cover board 62 and the prefabricatedroofing panel composite 80. - With the high-density polymer or predominantly polymer
material cover board 62, the low-density polymer or predominantly polymer materialfoam insulation board 64, and the high-density polymer or predominantlypolymer material baseboard 66 of the prefabricatedroofing panel composites station 306 to form a continuous length of the prefabricatedroofing panel composite roofing panel composite roofing panel composite roofing panel composite station 306 to length. - While the
production line 300, as shown, is capable of applying fourfacer materials baseboard 66, theinsulation board 64 and thecover board 62 to form the prefabricatedroofing panel composites materials roofing panel composite 60 and all but the top facing material can be omitted to form the prefabricatedroofing panel composite 80 with the desired number of facers. Thefacers precursors -
FIG. 10 is a schematic side view of anotherproduction line 400 that can be used with the method of the subject invention to continuously make prefabricated roofing panel composites of the subject invention in line, such as the prefabricatedroofing panel composites 30 ofFIG. 3 and 50 ofFIG. 4 . The prefabricatedroofing panel composites material cover board 32 and a low-density polymer or predominantly polymer materialfoam insulation board 34. Theproduction line 400 includes: a formingstation 402 for forming the low-density polymer or predominantly polymer materialfoam insulation board 34 and the high-density polymer or predominantly polymermaterial cover board 32 of the prefabricatedroofing panel composites station 404 for cutting the prefabricatedroofing panel composites - The forming
station 402 for forming the low-densityfoam insulation board 34 and the high-density cover board includes aconventional dispenser 406 for dispensing a low-density polymer or predominantly polymer material foam precursor 408 (e.g. a low-density polyisocyanurate or predominantly polyisocyanurate foam precursor) onto a facer, when used, overlying aconveyor 410 of two spaced-apart opposed formingconveyers conveyor 410. The formingstation 402 also includes aconventional dispenser 414 for dispensing a high-density polymer or predominantly polymer material precursor 416 (e.g. a high-density polyisocyanurate or predominantly polyisocyanurate material precursor) onto the low-density polymer or predominantly polymer material foam precursor of thecore layer 42 or, when used, a common facer overlying the low-density polymer or predominantly polymer material foam precursor of thecore layer 42. As the layers ofprecursor conveyors conveyors foam core layer 42 ofinsulation board 34 formed from theprecursor 408, the thickness of the high-density polymer or predominantly polymermaterial core layer 40 ofcover board 32 formed from theprecursor 416, and the thickness of the prefabricatedroofing panel composite station 402 also includes supplies (e.g. rolls) offacer materials material foam precursor 408 to form a common facer of the prefabricatedroofing panel composites roofing panel composites polymer material precursor 416 to form a top facer of the prefabricatedroofing panel composites - With the high-
density core layer 40 and the low-densityfoam core layer 42 of the prefabricatedroofing panel composite roofing panel composite roofing panel composite roofing panel composite reciprocating cutter 424, cuts the prefabricatedroofing panel composite station 402 to length. - While the
production line 400, as shown, is capable of applying threefacer materials insulation board 34 and thecover board 32 to form the prefabricatedroofing panel composites materials roofing panel composite 30 and all but the top facing material can be omitted to form the prefabricatedroofing panel composite 50 with the desired number of facers. Thefacers precursors - Preferably, the low-density polymer or predominantly polymer
material foam precursors polymer material precursors polymer material precursors precursors precursors - In describing the invention, certain embodiments have been used to illustrate the invention and the practices thereof. However, the invention is not limited to these specific embodiments as other embodiments and modifications within the spirit of the invention will readily occur to those skilled in the art on reading this specification. For example, the prefabricated roofing panel composites could be in an upside down orientation to that shown and described in connection with FIGS. 7 to 9. Thus, the invention is not intended to be limited to the specific embodiments disclosed, but is to be limited only by the claims appended hereto.
Claims (29)
1. A cover board for overlying low-density insulation of a roofing system, comprising:
a high-density predominantly polymer material core layer with a density between 6 lbs/ft3 and 25 lbs/ft3; the high-density predominantly polymer material core layer having a length, a width, and a thickness; the high density predominantly polymer material core layer having a top major surface and a bottom major surface that are each defined by the length and the width of the high density predominantly polymer material core layer.
2. The cover board for overlying low-density insulation of a roofing system according to claim 1 , wherein:
the thickness of the high-density predominantly polymer material core layer is between about 0.08 inches and about 0.75 inches; and the high-density predominantly polymer material core layer is a high-density predominantly polyisocyanurate polymer material core layer.
3. The cover board for overlying low-density insulation of a roofing system according to claim 1 , wherein:
the thickness of the high-density predominantly polymer material core layer is between about 0.08 inches and about 0.75 inches; and the high-density predominantly polymer material core layer is a high-density predominantly polyisocyanurate polymer material foam core layer.
4. The cover board for overlying low-density insulation of a roofing system according to claim 1 , wherein:
a waterproofing membrane overlies and is bonded to the top major surface of the high-density predominantly polymer material core layer and the high-density predominantly polymer material core layer is a high-density predominantly polyisocyanurate material core layer.
5. The cover board for overlying low-density insulation of a roofing system according to claim 1 , wherein:
a waterproofing membrane overlies and is bonded to the top major surface of the high-density predominantly polymer material core layer; the bottom major surface of the high-density predominantly polymer material core layer forms a bottom major surface of the cover board; and the high-density predominantly polymer material core layer is a high-density predominantly polyisocyanurate material foam core layer.
6. A prefabricated roofing system panel comprising:
a cover board; the cover board comprising a high-density predominantly polymer material core layer; the high-density core layer of the cover board having a density between 6 lbs/ft3 and 25 lbs/ft3; the high-density core layer of the cover board having a length, a width, and a thickness; the high density core layer of the cover board having a top major surface and a bottom major surface that are each defined by the length and the width of the high density core layer;
an insulation board, the insulation board comprising a low-density predominantly polymer material foam core layer; the low-density foam core layer of the insulation board having a density less than 6 lbs/ft3; the low-density foam core layer of the insulation board having a length, a width, and a thickness; the low-density foam core layer of the insulation board having a top major surface and a bottom major surface that are each defined by the length and the width of the low-density foam core layer; and
the bottom major surface of the high-density core layer of the cover board being bonded to the top major surface of the low-density foam core layer of the insulation board; and the bottom major surface of the high-density core layer of the cover board and the top major surface of the low-density foam core layer of the insulation board being substantially coextensive.
7. The prefabricated roofing system panel according to claim 6 , wherein:
the thickness of the high-density core layer of the cover board is about 0.08 inches or greater; the thickness of the low density foam core layer of the insulation board is about 0.50 inches or greater; and the lengths and widths of the high-density core layer of the cover board and the low-density foam core layer of the insulation board are each about 4 feet or greater.
8. The prefabricated roofing system panel according to claim 6 , wherein:
the thickness of the high-density core layer of the cover board is between about 0.08 inches and about 0.75 inches; the thickness of the low-density foam core layer of the insulation board is between about 0.50 inches and about 6 inches; the lengths of the high-density core layer of the cover board and the low-density foam core layer of the insulation board are each about 8 feet or greater; and the widths of the high-density core layer of the cover board and the low-density foam core layer of the insulation board are each about 4 feet or greater.
9. The prefabricated roofing system panel according to claim 6 , wherein:
the polymer material of the high-density core layer of the cover board and the low-density foam core layer of the insulation board is polyisocyanurate.
10. The prefabricated roofing system panel according to claim 6 , wherein:
the high-density core layer of the cover board is a high-density predominantly polymer material foam core layer.
11. The prefabricated roofing system panel according to claim 6 , wherein:
the cover board includes a top facer that overlies and is bonded to the top major surface of the high-density core layer of the cover board;
the insulation board includes a bottom facer that overlies and is bonded to the bottom major surface of the low-density foam core layer of the insulation board; and
the cover board and the insulation board have a common facer that overlies and is bonded to the bottom major surface of the high-density core layer of the cover board and the top major surface of the low-density foam core layer of the insulation board.
12. The prefabricated roofing system panel according to claim 11 , wherein:
the top facer of the cover board is a waterproofing membrane.
13. The prefabricated roofing system panel according to claim 6 , including:
a baseboard comprising a high-density predominantly polymer material core layer; the high-density core layer of the baseboard having a density between 6 lbs/ft3 and 25 lbs/ft3; the high-density core layer of the baseboard having a length, a width, and a thickness; the high-density core layer of the baseboard having a top major surface and a bottom major surface that are defined by the length and the width of the high-density core layer of the baseboard; and
the bottom major surface of the low-density foam core layer of the insulation board being bonded to the top major surface of the high-density core layer of the baseboard; and the bottom major surface of the low-density foam core layer of the insulation board and the top major surface of the high-density core layer of the baseboard being substantially coextensive.
14. The prefabricated roofing system panel according to claim 13 , wherein:
the cover board includes a top facer that overlies and is bonded to the top major surface of the high-density core layer of the cover board;
the baseboard includes a bottom facer that overlies and is bonded to the bottom major surface of the high-density core layer of the baseboard;
the cover board and the insulation board have a common facer that overlies and is bonded to the bottom major surface of the high-density core layer of the cover board and the top major surface of the low-density foam core layer of the insulation board; and
the baseboard and the insulation board have a common facer that overlies and is bonded to the top major surface of the high-density core layer of the baseboard and the bottom major surface of the low-density foam core layer of the insulation board.
15. The prefabricated roofing system panel according to claim 14 , wherein:
the top facer of the cover board is a waterproofing membrane.
16. A method of making prefabricated roofing system panels, comprising:
forming an insulation board comprising a low-density predominantly polymer material foam core layer having a density of less than 6 lbs/ft3 in a continuous process wherein the low-density foam core layer of the insulation board formed has a width, a thickness, a continuous length, and a top major surface and a bottom major surface that are each defined by the length and the width of the low-density foam core layer of the insulation board;
forming a cover board comprising a high-density predominantly polymer material core layer having a density between 6 lbs/ft3 and 25 lbs/ft3 in a continuous process wherein the high-density core layer of the cover board formed has a width, a thickness, a continuous length, and a top major surface and a bottom major surface that are each defined by the length and the width of the high-density core layer of the cover board; and
forming the widths of the low-density foam core layer of the insulation board and the high-density core layer of the cover board to be substantially the same with the core layer of one of the boards being formed over and bonded to one of the major surfaces of the core layer of the other board to form a composite.
17. The method of making prefabricated roofing system panels according to claim 16 , wherein:
the core layers of the insulation board and the cover board are formed concurrently.
18. The method of making prefabricated roofing system panels according to claim 15 , wherein:
the thickness of the high-density core layer of the cover board is about 0.08 inches or greater; the thickness of low-density foam core layer of the insulation board is about 0.50 inches or greater; the widths of the high-density foam core layer of the cover board and the low-density foam core layer of the insulation board are each about 4 feet or greater; and the composite formed by the high-density foam core layer of the cover board and the low-density foam core layer of the insulation board is periodically cut to form roofing systems panels that are each about 4 feet or greater in length.
19. The method of making prefabricated roofing system panels according to claim 16 , wherein:
the thickness of high-density core layer of the cover board is between about 0.08 inches and about 0.75 inches; the thickness of the low-density foam core layer of the insulation board is between about 0.50 inches and about 6 inches; the widths of the high-density foam core layer of the cover board and the low-density foam core layer of the insulation board are each about 4 feet or greater; and the composite formed by the high-density core layer of the cover board and the low-density foam core layer of the insulation board is periodically cut to form roofing system panels that are each about 8 feet or greater in length.
20. The method of making prefabricated roofing system panels according to claim 16 , wherein:
the polymer material of the high-density core layer of the cover board and the low-density foam core layer of the insulation board is polyisocyanurate.
21. The method of making prefabricated roofing system panels according to claim 16 , wherein:
the high-density core layer of the cover board is formed over and bonded to the top major surface of the low-density foam core layer of the insulation board.
22. The method of making prefabricated roofing system panels according to claim 16 , including:
applying a top facer to the low-density foam core layer of the insulation board during the formation of the low-density foam core layer of the insulation board that overlies and is bonded to the top major surface of the low-density foam core layer of the insulation board and applying a bottom facer to the low-density foam core layer of the insulation board during the formation of the low-density foam core layer of the insulation board that overlies and is bonded to the bottom major surface of the low-density foam core layer of the insulation board;
applying a top facer to the high-density core layer of the cover board during the formation of the high-density core layer of the cover board that overlies and is bonded to the top major surface of the high-density core layer of the cover board; and
forming the high-density core layer of the cover board on the top facer of the low-density foam core layer of the insulation board whereby the top facer of the low-density foam core layer of the insulation board becomes a common facer for the high-density foam core layer of the cover board and the low-density foam core layer of the insulation board.
23. The method of making prefabricated roofing system panels according to claim 22 , wherein:
the top facer applied to the top major surface of the high-density core layer of the cover board is a waterproofing membrane.
24. A method of making prefabricated roofing system panels, comprising:
feeding a series of insulation boards that each comprise a low-density predominantly polymer material foam core layer having a density of less than 6 lbs/ft3 into a production line in a continuous process; the low-density foam core layer of each of the insulation boards having a width, a thickness, a length, and a top major surface and a bottom major surface that are each defined by the length and the width of the low-density foam core layer of the insulation board;
forming a cover board comprising a high-density predominantly polymer material core layer having a density between 6 lbs/ft3 and 25 lbs/ft3 and a width substantially equal to the widths of the low-density foam core layers of the insulation boards; the high-density core layer of the cover board being formed in a continuous process over and bonded to the top major surfaces of the low-density foam core layers of the insulation boards fed into the production line to form a composite; and
the composite being cut to the lengths of the low-density foam core layers of the insulation boards fed into the production line.
25. The method of making prefabricated roofing system panels according to claim 24 , wherein:
the thickness of the high-density core layer of the cover board is about 0.08 inches or greater; the thickness of low-density foam core layer of each of the insulation boards is about 0.50 inches or greater; the widths of the high-density core layer of the cover board and the low-density foam core layers of each of the insulation boards are each about 4 feet or greater; and the composite formed by the high-density core layer of the cover board and the low-density foam core layers of each of the insulation boards is periodically cut to form roofing systems panels that are each about 4 feet or greater in length.
26. The method of making prefabricated roofing system panels according to claim 24 , wherein:
the thickness of high-density core layer of the cover board is between about 0.08 inches and about 0.75 inches; the thickness of the low-density foam core layer of each of the insulation boards is between about 0.50 inches and about 6 inches; the widths of the high-density core layer of the cover board and the low-density foam core layers of each of the insulation boards are each about 4 feet or greater; and the composite formed by the high-density core layer of the cover board and the low-density foam core layers of each of the insulation boards is periodically cut to form roofing system panels that are each about 8 feet or greater in length.
27. The method of making prefabricated roofing system panels according to claim 24 , wherein:
the polymer material of the high-density core layer of the cover board and the low-density foam core layers of each of the insulation boards is polyisocyanurate.
28. The method of making prefabricated roofing system panels according to claim 24 , wherein:
the low-density foam core layers of each of the insulation boards have top and bottom facers that overlie and are bonded to the top and bottom major surfaces of the low-density foam core layers of each of the insulation boards; and
a top facer is applied to the high-density core layer of the cover board during the formation of the high-density core layer of the cover board that overlies and is bonded to a top major surface of the high-density core layer of the cover board and the top facers of the low-density foam core layers of the insulation boards become a bottom facer for the high-density core layer of the cover board.
29. The method of making prefabricated roofing system panels according to claim 28 , wherein:
the top facer applied to the top major surface of the high-density core layer of the cover board is a waterproofing membrane.
Priority Applications (19)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/984,122 US20060096205A1 (en) | 2004-11-09 | 2004-11-09 | Roofing cover board, roofing panel composite, and method |
EP05849184.6A EP1815079B1 (en) | 2004-11-09 | 2005-11-07 | Prefabricated roofing system panel and method of making such panels |
CA2586357A CA2586357C (en) | 2004-11-09 | 2005-11-07 | Roofing cover board, roofing panel composite, and method |
PCT/US2005/040104 WO2006052789A2 (en) | 2004-11-09 | 2005-11-07 | Roofing cover board, roofing panel composite, and method |
US11/408,231 US7718253B2 (en) | 2004-11-09 | 2006-04-20 | Roofing cover board, roofing panel composite, and method |
US11/519,042 US7811663B2 (en) | 2004-11-09 | 2006-09-11 | Roofing cover board, roofing panel composites, and method |
US12/703,308 US8105685B2 (en) | 2004-11-09 | 2010-02-10 | Roofing cover board, roofing panel composites, and method |
US12/754,141 US20100189977A1 (en) | 2004-11-09 | 2010-04-05 | Roofing cover board, roofing panel composite, and method |
US12/792,901 US8426017B2 (en) | 2004-11-09 | 2010-06-03 | Roofing cover board, roofing panel composites, and method |
US13/209,710 US8479467B2 (en) | 2004-11-09 | 2011-08-15 | Prefabricated roofing panel composite |
US13/442,946 US8287997B2 (en) | 2004-11-09 | 2012-04-10 | Roofing cover board, roofing panel composites, and method |
US13/758,034 US8597779B2 (en) | 2004-11-09 | 2013-02-04 | Roofing system including roofing components and methods |
US13/758,111 US8617699B2 (en) | 2004-11-09 | 2013-02-04 | Manufacturing and assembly of roofing components |
US13/758,077 US8470436B1 (en) | 2004-11-09 | 2013-02-04 | Roofing system including insulation and cover boards |
US13/908,505 US20130264012A1 (en) | 2004-11-09 | 2013-06-03 | Prefabricated roofing panel composite |
US14/293,004 US9404261B2 (en) | 2004-11-09 | 2014-06-02 | Roofing systems and methods |
US15/193,729 US9909317B2 (en) | 2004-11-09 | 2016-06-27 | Roofing systems and methods |
US15/874,770 US10087634B2 (en) | 2004-11-09 | 2018-01-18 | Roofing systems and methods |
US16/122,771 US20180371758A1 (en) | 2004-11-09 | 2018-09-05 | Roofing systems and methods |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/984,122 US20060096205A1 (en) | 2004-11-09 | 2004-11-09 | Roofing cover board, roofing panel composite, and method |
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US13/758,077 Active US8470436B1 (en) | 2004-11-09 | 2013-02-04 | Roofing system including insulation and cover boards |
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US20160305126A1 (en) | 2016-10-20 |
US20130139470A1 (en) | 2013-06-06 |
US8105685B2 (en) | 2012-01-31 |
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US8426017B2 (en) | 2013-04-23 |
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WO2006052789A3 (en) | 2007-12-27 |
US20130145722A1 (en) | 2013-06-13 |
US20100313514A1 (en) | 2010-12-16 |
US20130139471A1 (en) | 2013-06-06 |
CA2586357A1 (en) | 2006-05-18 |
EP1815079A4 (en) | 2009-10-21 |
EP1815079A2 (en) | 2007-08-08 |
US10087634B2 (en) | 2018-10-02 |
US8287997B2 (en) | 2012-10-16 |
CA2586357C (en) | 2010-06-15 |
US20120196106A1 (en) | 2012-08-02 |
US20110131910A1 (en) | 2011-06-09 |
WO2006052789A2 (en) | 2006-05-18 |
US7718253B2 (en) | 2010-05-18 |
US20060260237A1 (en) | 2006-11-23 |
EP1815079B1 (en) | 2021-01-06 |
US8597779B2 (en) | 2013-12-03 |
US20070022711A1 (en) | 2007-02-01 |
US20180371758A1 (en) | 2018-12-27 |
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