Composite roofing members having improved dimensional stability and related methods

• US 6,044,604 A
• Filed: 08/10/1998
• Issued: 04/04/2000
• Est. Priority Date: 09/23/1996
• Status: Expired due to Term

• Current Assignee: Firestone Building Products Company LLC (Bridgestone Corporation)
• Original Assignee: Bridgestone Firestone North American Tire LLC (Bridgestone Corporation)
• Inventors: Letts, John B., Clayton, Thomas M.
• Primary Examiner(s): Kent, Christopher T.
• Application Number:
  US09/131,482
• Time in Patent Office: 603 Days
• Field of Search: 52/309.9, 52/794.1, 52/796.1, 52/746.11, 52/745.05, 52/745.13
• US Class Current: 52/309.9
• CPC Class Codes: E04C 2/246 combinations of materials fully covered by E04C2/16 and E04C2/20
• 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 3/352 at least one insulating layer being located between non-insulating layers, e.g. double skin slabs or sheets

Abstract

A composite recovery board (10) containing a foam core (11) of polyisocyanurate, polyurethane materials or mixtures thereof; a facer (15), applied to one major surface (13) of the foam core, where the facer includes polymer materials, reinforced polymer materials, cellulosic materials, paper, aluminum foil or trilaminates thereof, wherein the reinforced polymer material and the cellulosic material are reinforced with glass strands, glass fibers, or mixtures thereof; and, gypsum board (14), applied to the opposite major surface (12) of the foam core. A method of reroofing a roof by applying composite recovery boards of the present invention to a roof deck; and, applying a weather protective layer over the recovery boards. A continuous method of making a composite recovery board by feeding gypsum board (14) into a laminator assembly (21); depositing a foamable polymer liquid (36) onto the gypsum board; feeding a facer material (15) into the laminator assembly above the foamable polymer liquid; allowing the polymer liquid to rise between the gypsum board and facer material forming polymer foam of a pre-determined thickness; curing the polymer foam under heat (44) to create the composite board; and cutting the composite board to desired lengths.

Claims

1. A composite recovery board comprising:

a foam core selected from the group consisting of polyisocyanurate, polyurethane materials, and mixtures thereof;

a facer applied to one major surface of said foam core and comprising a sheet selected from the group consisting of polymer materials selected from the group consisting of polypropylene, polyamides, polymer latexes, and mixtures thereof, reinforced polymer materials, cellulosic materials, paper, aluminum foil and trilaminates thereof, wherein said latter polymer materials and said cellulosic materials are reinforced with a material selected from the group consisting of glass strands, glass fibers, and mixtures thereof; and

a gypsum board, applied to the opposite major surface of said foam core.

2. A composite board, as set forth in claim 1, wherein said sheets contain a filler selected from the group consisting of clay, mica, talc, limestone, gypsum, aluminum trihydrate, antimony oxide, cellulose fibers, plastic polymer fibers, and mixtures thereof in an amount of from 0 to about 5000 parts by weight, based upon 100 parts by weight of the material selected to form the facer.

3. A composite board, as set forth in claim 1, wherein said foam core comprises polyisocyanurate having an index above 200.

4. A composite board, as set forth in claim 1, wherein said foam core comprises polyurethane having an index above 120.

5. A composite board, as set forth in claim 1, wherein said facer has a thickness in the range from about 0.0005 to about 0.15 inches.

6. A composite board, as set forth in claim 1, wherein said facer comprises said reinforcing material in an amount from about 1 to about 10,000 parts by weight, based upon 100 parts by weight of the material selected to form the facer.

7. A composite board, as set forth in claim 1, wherein said reinforced cellulosic materials comprise 83 percent by weight cellulosic fibers, 14 percent by weight glass fibers, 1 percent by weight carbon black, and 2 percent by weight of a binding agent.

8. A composite board, as set forth in claim 7, wherein said sheet comprises a polypropylene/polymer latex mixture, said latex being selected from the group consisting of including styrene-butadiene rubber, polyvinyl chloride and polyvinyl alcohol.

9. A method of reroofing a roof comprising:

Applying composite recovery boards to a roof deck, said recovery boards comprising

a foam core selected from the group consisting of polyisocyanurate, polyurethane materials, and mixtures thereof;

a facer applied to one major surface of said foam core and comprising a sheet selected from the group consisting of polymer materials selected from the group consisting of polypropylene, polyamides, polymer latexes, and mixtures thereof reinforced polymer materials, cellulosic materials, paper, aluminum foil and trilaminates thereof, wherein said latter polymer materials and said cellulosic materials are reinforced with a material selected from the group consisting of glass strands, glass fibers, and mixtures thereof; and

a gypsum board, applied to the opposite major surface of said foam core.

10. A method of reroofing a roof, as set forth in claim 9, wherein said foam core comprises polyisocyanurate having an index above 200.

11. A method of reroofing a roof, as set forth in claim 9, wherein said foam core comprises polyurethane having an index above 120.

12. A method of reroofing a roof, as set forth in claim 9, wherein said facer has a thickness in the range from about 0.0005 to about 0.15 inches.

13. A method of reroofing a roof, as set forth in claim 9, wherein said facer comprises said reinforcing material in an amount from about 1 to about 10,000 parts by weight, based upon 100 parts by weight of the material selected to form the facer.

14. A method of reroofing a roof, as set forth in claim 9, wherein said sheets contain a filler selected from the group consisting of clay, mica, talc, limestone, gypsum, aluminum trihydrate, antimony oxide, cellulose fibers, plastic polymer fibers, and mixtures thereof in an amount of from 0 to about 5000 parts by weight, based upon 100 parts by weight of the material selected to form the facer.

15. A method of reroofing a roof, as set forth in claim 9, wherein said reinforced cellulosic materials comprise 83 percent by weight cellulosic fibers, 14 percent by weight glass fibers, 1 percent by weight carbon black, and 2 percent by weight of a binding agent.

16. A method of reroofing a roof, as set forth in claim 15, wherein said sheet comprises a polypropylene/polymer latex mixture, said latex being selected from the group consisting of styrene-butadiene rubber, polyvinyl chloride and polyvinyl alcohol.

17. A composite recovery board comprising:

a foam core selected from the group consisting of polyisocyanurate, polyurethane materials, and mixtures thereof;

a facer applied to one major surface of said foam core and comprising a sheet that is a trilaminate of aluminum foil, kraft paper, and aluminum foil; and

a gypsum board, applied to the opposite major surface of said foam core.