Roofing members without auxiliary facers and related methods
First Claim
1. A continuous method of making a facerless insulation board comprising the steps of:
- feeding a first sheet of temporary facer material into a laminator;
depositing a foamable polymer liquid onto the first sheet;
feeding a second sheet of temporary facer material into said laminator above the foamable polymer liquid;
allowing the polymer liquid to rise between the first and second sheets forming polymer foam of a pre-determined thickness;
curing the polymer foam under heat to create the insulation board;
removing the first and second sheets from the board prior to final curing and cooling;
cutting the board to desired lengths; and
stacking a plurality of said boards in a separator assembly for additional curing and subsequent stacking;
wherein said separator assembly comprises a plurality of arm members attached at one end to a frame member, and wherein said step of stacking includesplacing a first board onto one of said arms;
positioning a subsequent arm over said first board;
repeating said steps of placing and positioning to form a bundle of said boards within said separator assembly; and
storing said boards in said bundle for a period of time sufficient to allow said boards to become dimensionally stable.
2 Assignments
0 Petitions
Accused Products
Abstract
An insulation board (10) insulation board comprising a foam core (11) selected from the group consisting of polyisocyanurate and polyurethane materials and mixtures thereof; the board being devoid of facers. A method of covering roofs comprises applying insulation boards to a roof deck, the insulation boards comprising a foam core selected from the group consisting of polyisocyanurate and polyurethane materials and mixtures thereof, the boards being devoid of facers; and, applying a weather protective layer over the insulation boards. A continuous method of making a facerless insulation board comprising the steps of feeding a first sheet (24) of temporary facer material into a laminator (25); depositing a foamable polymer liquid (40) onto the first sheet; feeding a second sheet (23) of temporary facer material into the laminator above the foamable polymer liquid; allowing the polymer liquid to rise between the first and second sheets forming polymer foam (44) of a pre-determined thickness; curing the polymer foam under heat (45) to create the insulation board; removing the first and second sheets from the board prior to final curing and cooling; and cutting the board to desired lengths.
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Citations
8 Claims
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1. A continuous method of making a facerless insulation board comprising the steps of:
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feeding a first sheet of temporary facer material into a laminator; depositing a foamable polymer liquid onto the first sheet; feeding a second sheet of temporary facer material into said laminator above the foamable polymer liquid; allowing the polymer liquid to rise between the first and second sheets forming polymer foam of a pre-determined thickness; curing the polymer foam under heat to create the insulation board; removing the first and second sheets from the board prior to final curing and cooling; cutting the board to desired lengths; and stacking a plurality of said boards in a separator assembly for additional curing and subsequent stacking;
wherein said separator assembly comprises a plurality of arm members attached at one end to a frame member, and wherein said step of stacking includesplacing a first board onto one of said arms; positioning a subsequent arm over said first board; repeating said steps of placing and positioning to form a bundle of said boards within said separator assembly; and storing said boards in said bundle for a period of time sufficient to allow said boards to become dimensionally stable. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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Specification