Roofing cover board, roofing panel composite, and method

• US 20060096205A1
• Filed: 11/09/2004
• Published: 05/11/2006
• Est. Priority Date: 11/09/2004
• Status: Abandoned Application

• Current Assignee: Johns Manville Corporation (Berkshire Hathaway Incorporated)
• Original Assignee: Johns Manville Corporation (Berkshire Hathaway Incorporated)
• Inventors: Swann, Raymond C., Hazy, Joel Evan, Griffin, Christopher J., Burdic, Brad C.
• Application Number:
  US10/984,122
• Publication Number:
  US 20060096205A1
• Time in Patent Office: Days
• US Class Current: 52/309.4
• CPC Class Codes: B29C 44/24 Making multilayered articles
• CPC Class Codes: B29C 44/326 Joining the preformed parts, e.g. to make flat or profiled sandwich laminates
• CPC Class Codes: B29D 99/001 Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings articles with hollow walls B29D24/00
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B32B 2038/0084 Foaming
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2307/72 Density
• CPC Class Codes: B32B 2419/06 Roofs, roof membranes
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/40 comprising polyurethanes
• CPC Class Codes: B32B 27/42 comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
• CPC Class Codes: B32B 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/24 one layer being a fibrous or filamentary layer
• CPC Class Codes: B32B 7/02 Physical, chemical or physicochemical properties
• CPC Class Codes: E04C 2/205 of foamed plastics, or of plastics and foamed plastics, optionally reinforced
• CPC Class Codes: E04C 2/284 at least one of the materials being insulating
• CPC Class Codes: E04C 2/296 composed of insulating material and non-metallic or unspecified sheet-material E04C2/288 takes precedence
• CPC Class Codes: E04D 12/00 Non-structural supports for roofing materials, e.g. battens, boards E04D11/02 and E04D13/16 take precedence; self-supporting slabs with non-structural supports for roofing materials E04B7/205
• CPC Class Codes: E04D 3/18 of specified materials, or of combinations of materials, not covered by any of groups E04D3/04, E04D3/06 or E04D3/16
• CPC Class Codes: E04D 3/351 : at least one of the layers being composed of insulating material, e.g. fibre or foam material
• CPC Class Codes: E04D 3/352 : at least one insulating layer being located between non-insulating layers, e.g. double skin slabs or sheets
• CPC Class Codes: E04D 3/354 : more than one of the layers being composed of insulating material
• CPC Class Codes: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 428/24331 : including nonapertured component
• CPC Class Codes: Y10T 428/24967 : Absolute thicknesses specified
• CPC Class Codes: Y10T 428/24992 : Density or compression of components
• CPC Class Codes: Y10T 428/249953 : Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/24998 : Composite has more than two layers
• CPC Class Codes: Y10T 428/249987 : With nonvoid component of specified composition
• CPC Class Codes: Y10T 428/249989 : Integrally formed skin

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.

Claims

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.

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.

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.

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.