Roofing cover board, roofing panel composite, and method

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

BACKGROUND OF THE INVENTION [0001] 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 [0002] 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...

AI Technical Summary

Benefits of technology

[0003] 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.

Problems solved by technology

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.

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