U.S. patent application number 12/837054 was filed with the patent office on 2011-02-10 for facer and faced polymeric roofing board.
Invention is credited to Gaurav Agrawal.
Application Number | 20110033684 12/837054 |
Document ID | / |
Family ID | 46323810 |
Filed Date | 2011-02-10 |
United States Patent
Application |
20110033684 |
Kind Code |
A1 |
Agrawal; Gaurav |
February 10, 2011 |
FACER AND FACED POLYMERIC ROOFING BOARD
Abstract
A prefabricated, faced roofing board composite includes a first
board layer made of a polymeric material or a predominantly
polymeric material and a fire and weather resistant
fiberglass-based facer bonded to a top major surface of the first
board layer and forming a top major surface of the composite. The
fiberglass-based facer is substantially impervious to the passage
of hot gases of combustion, water, and water vapor through the
thickness of the fiberglass-based facer. The faced composite can be
a cover board, an insulation board; can include cover board and
insulation board layers; and can include cover board, insulation
board, and baseboard layers. A second fiberglass-based facer that
is substantially impervious to the passage of hot gases of
combustion through its thickness can form a bottom major surface of
the composite. The polymeric material or predominantly polymeric
material of the board layer to which each fiberglass-based facer is
bonded penetrates part of the way through, but not completely
through, the fiberglass-based facer.
Inventors: |
Agrawal; Gaurav; (Aurora,
CO) |
Correspondence
Address: |
JOHNS MANVILLE
10100 WEST UTE AVENUE, PO BOX 625005
LITTLETON
CO
80162-5005
US
|
Family ID: |
46323810 |
Appl. No.: |
12/837054 |
Filed: |
July 15, 2010 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
11305783 |
Feb 9, 2006 |
7785703 |
|
|
12837054 |
|
|
|
|
11126583 |
May 11, 2005 |
7749598 |
|
|
11305783 |
|
|
|
|
Current U.S.
Class: |
428/218 ; 169/48;
428/219; 428/317.1 |
Current CPC
Class: |
Y10T 428/249986
20150401; Y10T 428/239 20150115; Y10T 428/249987 20150401; Y10T
442/652 20150401; E04D 3/351 20130101; B32B 27/40 20130101; B32B
5/18 20130101; B32B 17/02 20130101; Y10T 428/24992 20150115; Y10T
428/249991 20150401; Y10T 428/249989 20150401; Y10T 428/249982
20150401 |
Class at
Publication: |
428/218 ; 169/48;
428/317.1; 428/219 |
International
Class: |
A62C 3/00 20060101
A62C003/00; B32B 7/12 20060101 B32B007/12; B32B 5/00 20060101
B32B005/00; B32B 5/14 20060101 B32B005/14 |
Claims
1. A facer for improving the fire resistance and weathering
properties of a polymeric material roofing board, comprising: a
fire and weather resistant fiberglass-based facer having a length,
a width, and a thickness; the fiberglass-based facer having first
and second major surfaces that are each defined by the length and
the width of the fiberglass-based facer; the fiberglass-based facer
having a Gurley Porosity of at least 300 and being substantially
impervious to the passage of hot gases of combustion and water
vapor through the thickness of the fiberglass-based facer; and the
fiberglass-based facer having a structure for permitting a limited
penetration of a liquid polymeric mixture through the first major
surface of the fiberglass-based facer into, but only part of the
way through, the fiberglass-based facer when the fiberglass-based
facer overlies the liquid polymeric mixture during the formation of
a polymeric roofing board from the liquid polymeric mixture to
effect a strong bond between the fiberglass-based facer and the
polymeric roofing board thus formed without permitting the liquid
polymeric mixture to pass through the fiberglass-based facer to the
second major surface.
2. The facer for improving the fire resistance and weathering
properties of a polymeric material roofing board according to claim
1, wherein: the fiberglass-based facer comprises an uncoated
fiberglass mat that, in of itself, is substantially impervious to
the passage of hot gases of combustion and water vapor.
3. The facer for improving the fire resistance and weathering
properties of a polymeric material roofing board according to claim
1, wherein: the fiberglass-based facer comprises an uncoated
fiberglass mat with mineral filler that combine to make the
fiberglass-based facer substantially impervious to the passage of
hot gases of combustion and water vapor.
4. The facer for improving the fire resistance and weathering
properties of a polymeric material roofing board according to claim
1, wherein: the fiberglass-based facer comprises an uncoated
fiberglass mat with a polymeric binder that combine to make the
fiberglass-based facer substantially impervious to the passage of
hot gases of combustion and water vapor.
5. The facer for improving the fire resistance and weathering
properties of a polymeric material roofing board according to claim
1, wherein: the fiberglass-based facer comprises an uncoated
fiberglass mat with mineral filler and a mineral filler carrier
that combine to make the fiberglass-based facer substantially
impervious to the passage of hot gases of combustion and water
vapor.
6. The facer for improving the fire resistance and weathering
properties of a polymeric material roofing board according to claim
1, wherein: the fiberglass-based facer comprises a fiberglass mat
coated on the second major surface with a coating that contains
mineral filler and a mineral filler carrier which combine to make
the fiberglass-based facer substantially impervious to the passage
of hot gases of combustion and water vapor.
7. A prefabricated, faced roofing board composite, comprising: a
first board layer made of a polymeric material or a predominantly
polymeric material; and a first fire and weather resistant
fiberglass-based facer; the first board layer having a density, a
length, a width, and a thickness; the first board layer having a
top major surface and a bottom major surface that are each defined
by the length and the width of the first board layer; the first
fiberglass-based facer having a length, a width, and a thickness;
the first fiberglass-based facer having first and second major
surfaces that are each defined by the length and the width of the
first fiberglass-based facer; the first fiberglass-based facer
having a Gurley porosity of at least 300 and being substantially
impervious to the passage of hot gases of combustion and water
vapor through the thickness of the first fiberglass-based facer;
and the first fiberglass-based facer being substantially
coextensive with and bonded to the top major surface of the first
board layer; and the polymeric material or predominantly polymeric
material of the first board layer penetrating part of the way
through, but not completely through, the first fiberglass-based
facer from the first major surface of the first fiberglass-based
facer to effect a strong bond between the first fiberglass-based
facer and the first board layer while the second major surface of
the first fiberglass-based facer is free of the polymeric material
or predominantly polymeric material of the first board layer.
8. The prefabricated, faced roofing board composite according to
claim 7, wherein: the first fiberglass-based facer comprises an
uncoated fiberglass mat that, in of itself, is substantially
impervious to the passage of hot gases of combustion and water
vapor.
9. The prefabricated, faced roofing board composite according to
claim 7, wherein: the first fiberglass-based facer comprises an
uncoated fiberglass mat with mineral filler that combine with the
fiberglass mat to make the first fiberglass-based facer
substantially impervious to the passage of hot gases of combustion
and water vapor.
10. The prefabricated, faced roofing board composite according to
claim 7, wherein: the first fiberglass-based facer comprises an
uncoated fiberglass mat with a polymeric binder that combine with
the fiberglass mat to make the first fiberglass-based facer
substantially impervious to the passage of hot gases of combustion
and water vapor.
11. The prefabricated, faced roofing board composite according to
claim 7, wherein: the first fiberglass-based facer comprises an
uncoated fiberglass mat with a mineral filler and a mineral filler
carrier that combine with the fiberglass mat to make the first
fiberglass-based facer substantially impervious to the passage of
hot gases of combustion and water vapor.
12. The prefabricated, faced roofing board composite according to
claim 7, wherein: the first fiberglass-based facer comprises a
fiberglass mat coated on the second major surface with a coating
that contains mineral filler and a mineral filler carrier which
combine with the fiberglass mat to make the first fiberglass-based
facer substantially impervious to the passage of hot gases of
combustion and water vapor.
13. The prefabricated, faced roofing board composite according to
claim 7, wherein: the polymeric material or predominately polymeric
material of the first board layer has an average density between
about 1.2 lbs/ft.sup.3 and about 25 lbs/ft.sup.3.
14. The prefabricated, faced roofing board composite according to
claim 7, wherein: the polymeric material or predominately polymeric
material of the first board layer has an average density between 6
lbs/ft.sup.3 and 25 lbs/ft.sup.3; and the prefabricated, faced
roofing board composite is a prefabricated, faced cover board
composite.
15. The prefabricated, faced roofing board composite according to
claim 7, wherein: the polymeric material or predominately polymeric
material of the first board layer is a high-density
polyisocyanurate or predominately polyisocyanurate material.
16. The prefabricated, faced roofing board composite according to
claim 7, wherein: the polymeric material or predominately polymeric
material of the first board layer has an average density of less
than 6 lbs/ft.sup.3; and the prefabricated, faced roofing board
composite is a prefabricated, faced insulation board composite.
17. The prefabricated, faced roofing board composite according to
claim 7, wherein: the polymeric material or predominately polymeric
material of the first board layer is a low-density polyisocyanurate
or predominately polyisocyanurate foam material.
18. The prefabricated, faced roofing board composite according to
claim 7, including: a second fire and weather resistant
fiberglass-based facer having a length, a width, and a thickness;
the second fiberglass-based facer having first and second major
surfaces that are each defined by the length and the width of the
second fiberglass-based facer; the second fiberglass-based facer
being substantially impervious to the passage of hot gases of
combustion through the thickness of the second fiberglass-based
facer; and the second fiberglass-based facer being substantially
coextensive with and bonded to the bottom major surface of the
first board layer; and the polymeric material or predominantly
polymeric material of the first board layer penetrating part of the
way through, but not completely through, the second
fiberglass-based facer from the first major surface of the second
fiberglass-based facer to effect a strong bond between the second
fiberglass-based facer and the first board layer while the second
major surface of the second fiberglass-based facer is free of the
polymeric material or predominantly polymeric material of the first
board layer.
19. The prefabricated, faced roofing board composite according to
claim 7, including: a second board layer made of a polymeric
material or a predominantly polymeric material; the second board
layer having a length, a width, and a thickness; the second board
layer having a top major surface and a bottom major surface that
are each defined by the length and the width of the second board
layer; the second board layer having a density that differs from
the density of the first board layer; and the top major surface of
the second board layer being substantially coextensive with and
bonded to the bottom major surface of the first board layer.
20. The prefabricated, faced roofing board composite according to
claim 19, wherein: the polymeric material or predominately
polymeric material of the first board layer has an average density
between 6 lbs/ft.sup.3 and 25 lbs/ft.sup.3; and the first board
layer forms a cover board layer of the prefabricated, faced roofing
board composite; and the polymeric material or predominately
polymeric foam material of the second board layer has an average
density less than 6 lbs/ft.sup.3; and the second board layer forms
an insulation board layer of the prefabricated, faced roofing board
composite.
21. The prefabricated, faced roofing board composite according to
claim 19, wherein: the polymeric material or predominately
polymeric material of the first board layer is a high-density
polyisocyanurate or predominately polyisocyanurate material; and
the polymeric material or predominately polymeric foam material of
the second board layer is a low-density polyisocyanurate or
predominately polyisocyanurate foam material.
22. The prefabricated, faced roofing board composite according to
claim 19, including: a second fire and weather resistant
fiberglass-based facer having a length, a width, and a thickness;
the second fiberglass-based facer having first and second major
surfaces that are each defined by the length and the width of the
second fiberglass-based facer; the second fiberglass-based facer
being substantially impervious to the passage of hot gases of
combustion through the thickness of the second fiberglass-based
facer; and the second fiberglass-based facer being substantially
coextensive with and bonded to the bottom major surface of the
second board layer; and the polymeric material or predominantly
polymeric foam material of the second board layer penetrating part
of the way through, but not completely through, the second
fiberglass-based facer from the first major surface of the second
fiberglass-based facer to effect a strong bond between the second
fiberglass-based facer and the second board layer while the second
major surface of the second fiberglass-based facer is free of the
polymeric material or predominantly polymeric foam material of the
second board layer.
23. The prefabricated, faced roofing board composite according to
claim 7, including: a second board layer made of a polymeric
material or a predominantly polymeric foam material; the second
board layer having a length, a width, and a thickness; the second
board layer having a top major surface and a bottom major surface
that are each defined by the length and the width of the second
board layer; the second board layer having a density that differs
from and is less than the density of the first board layer; and the
top major surface of the second board layer being substantially
coextensive with and bonded to the bottom major surface of the
first board layer; and a third board layer made of a polymeric
material or a predominantly polymeric material; the third board
layer having a length, a width, and a thickness; the third board
layer having a top major surface and a bottom major surface that
are each defined by the length and the width of the third board
layer; the third board layer having a density that differs from and
is greater than the density of the second board layer; and the top
major surface of the third board layer being substantially
coextensive with and bonded to the bottom major surface of the
second board layer.
24. The prefabricated, faced roofing board composite according to
claim 23, wherein: the polymeric material or predominately
polymeric material of the first board layer has an average density
between 6 lbs/ft.sup.3 and 25 lbs/ft.sup.3; and the first board
layer forms a cover board layer of the prefabricated, faced roofing
board composite; the polymeric material or predominately polymeric
foam material of the second board layer has an average density less
than 6 lbs/ft.sup.3; and the second board layer forms an insulation
board layer of the prefabricated, faced roofing board composite;
and the polymeric material or predominately polymeric material of
the third board layer has an average density between 6 lbs/ft.sup.3
and 25 lbs/ft.sup.3; and the third board layer forms a baseboard
layer of the prefabricated, faced roofing board composite.
25. The prefabricated, faced roofing board composite according to
claim 23, wherein: the polymeric material or predominately
polymeric material of the first and third board layers is a
high-density polyisocyanurate or predominately polyisocyanurate
material; and the polymeric material or predominately polymeric
foam material of the second board layer is a low-density
polyisocyanurate or predominately polyisocyanurate foam
material.
26. The prefabricated, faced roofing board composite according to
claim 23, including: a second fire resistant fiberglass-based facer
having a length, a width, and a thickness; the second
fiberglass-based facer having first and second major surfaces that
are each defined by the length and the width of the second
fiberglass-based facer; the second fiberglass-based facer being
substantially impervious to the passage of hot gases of combustion
through the thickness of the second fiberglass-based facer; and the
second fiberglass-based facer being substantially coextensive with
and bonded to the bottom major surface of the third board layer;
and the polymeric material or predominantly polymeric material of
the third board layer penetrating part of the way through, but not
completely through, the second fiberglass-based facer from the
first major surface of the second fiberglass-based facer to effect
a strong bond between the second fiberglass-based facer and the
third board layer while the second major surface of the second
fiberglass-based facer is free of the polymeric material or
predominantly polymeric material of the third board layer.
27. A facer for improving the fire resistance and weathering
properties of a polymeric material roofing board, comprising: a
fire and weather resistant fiberglass-based facer having a length,
a width, and a thickness; the fiberglass-based facer having first
and second major surfaces that are each defined by the length and
the width of the fiberglass-based facer; the fiberglass-based facer
comprising between about 15% and 25% by weight fiberglass mat and
between about 75% and 85% by weight a polymeric based coating
material containing an inorganic filler; the fiberglass based facer
being substantially impervious to the passage of hot gases of
combustion and water vapor through the thickness of the
fiberglass-based facer; and the fiberglass-based facer having a
structure for permitting a limited penetration of a liquid
polymeric mixture through the first major surface of the
fiberglass-based facer into, but only part of the way through, the
fiberglass-based facer when the fiberglass-based facer overlies the
liquid polymeric mixture during the formation of a polymeric
roofing board from the liquid polymeric mixture to effect a strong
bond between the fiberglass-based facer and the polymeric roofing
board thus formed without permitting the liquid polymeric mixture
to pass through the fiberglass-based facer to the second major
surface.
28. The facer for improving the fire resistance and weathering
properties of a polymeric material roofing board, according to
claim 27, wherein: the polymeric based coating material of the
fiberglass-based facer is a latex based coating material; and the
fiberglass-based facer has a Gurley porosity of at least 300.
29. A prefabricated, faced roofing board composite, comprising: a
first board layer made of a polymeric material or a predominantly
polymeric material; and a first fire and weather resistant
fiberglass-based facer; the first board layer having a density, a
length, a width, and a thickness; the first board layer having a
top major surface and a bottom major surface that are each defined
by the length and the width of the first board layer; the first
fiberglass-based facer having a length, a width, and a thickness;
the first fiberglass-based facer having first and second major
surfaces that are each defined by the length and the width of the
first fiberglass-based facer; the first fiberglass-based facer
comprising between about 15% and 25% by weight fiberglass mat and
between about 75% and 85% by weight a polymeric based coating
material containing an inorganic filler; the first fiberglass-based
facer being substantially impervious to the passage of hot gases of
combustion and water vapor through the thickness of the first
fiberglass-based facer; and the first fiberglass-based facer being
substantially coextensive with and bonded to the top major surface
of the first board layer; and the polymeric material or
predominantly polymeric material of the first board layer
penetrating part of the way through, but not completely through,
the first fiberglass-based facer from the first major surface of
the first fiberglass-based facer to effect a strong bond between
the first fiberglass-based facer and the first board layer while
the second major surface of the first fiberglass-based facer is
free of the polymeric material or predominantly polymeric material
of the first board layer.
30. The prefabricated, faced roofing board composite according to
claim 29, wherein: the polymeric based coating material of the
first fiberglass-based facer is a latex based coating material; and
the first fiberglass-based facer has a Gurley porosity of at least
300.
31. The prefabricated, faced roofing board composite according to
claim 29, wherein: the polymeric material or predominately
polymeric material of the first board layer has an average density
between about 1.2 lbs/ft.sup.3 and about 25 lbs/ft.sup.3.
32. The prefabricated, faced roofing board composite according to
claim 29, wherein: the polymeric material or predominately
polymeric material of the first board layer has an average density
between 6 lbs/ft.sup.3 and 25 lbs/ft.sup.3; and the prefabricated,
faced roofing board composite is a prefabricated, faced cover board
composite.
33. The prefabricated, faced roofing board composite according to
claim 29, wherein: the polymeric material or predominately
polymeric material of the first board layer is a high-density
polyisocyanurate or predominately polyisocyanurate material.
34. The prefabricated, faced roofing board composite according to
claim 29, wherein: the polymeric material or predominately
polymeric material of the first board layer has an average density
of less than 6 lbs/ft.sup.3; and the prefabricated, faced roofing
board composite is a prefabricated, faced insulation board
composite.
35. The prefabricated, faced roofing board composite according to
claim 29, wherein: the polymeric material or predominately
polymeric material of the first board layer is a low-density
polyisocyanurate or predominately polyisocyanurate foam
material.
36. The prefabricated, faced roofing board composite according to
claim 29, including: a second fire and weather resistant
fiberglass-based facer having a length, a width, and a thickness;
the second fiberglass-based facer having first and second major
surfaces that are each defined by the length and the width of the
second fiberglass-based facer; the second fiberglass-based facer
comprising between about 15% and 25% by weight fiberglass mat and
between about 75% and 85% by weight a polymeric based coating
material containing an inorganic filler; the second
fiberglass-based facer being substantially impervious to the
passage of hot gases of combustion through the thickness of the
second fiberglass-based facer; and the second fiberglass-based
facer being substantially coextensive with and bonded to the bottom
major surface of the first board layer; and the polymeric material
or predominantly polymeric material of the first board layer
penetrating part of the way through, but not completely through,
the second fiberglass-based facer from the first major surface of
the second fiberglass-based facer to effect a strong bond between
the second fiberglass-based facer and the first board layer while
the second major surface of the second fiberglass-based facer is
free of the polymeric material or predominantly polymeric material
of the first board layer.
37. The prefabricated, faced roofing board composite according to
claim 29, including: a second board layer made of a polymeric
material or a predominantly polymeric material; the second board
layer having a length, a width, and a thickness; the second board
layer having a top major surface and a bottom major surface that
are each defined by the length and the width of the second board
layer; the second board layer having a density that differs from
the density of the first board layer; and the top major surface of
the second board layer being substantially coextensive with and
bonded to the bottom major surface of the first board layer.
38. The prefabricated, faced roofing board composite according to
claim 37, wherein: the polymeric material or predominately
polymeric material of the first board layer has an average density
between 6 lbs/ft.sup.3 and 25 lbs/ft.sup.3; and the first board
layer forms a cover board layer of the prefabricated, faced roofing
board composite; and the polymeric material or predominately
polymeric foam material of the second board layer has an average
density less than 6 lbs/ft.sup.3; and the second board layer forms
an insulation board layer of the prefabricated, faced roofing board
composite.
39. The prefabricated, faced roofing board composite according to
claim 37, wherein: the polymeric material or predominately
polymeric material of the first board layer is a high-density
polyisocyanurate or predominately polyisocyanurate material; and
the polymeric material or predominately polymeric foam material of
the second board layer is a low-density polyisocyanurate or
predominately polyisocyanurate foam material.
40. The prefabricated, faced roofing board composite according to
claim 37, including: a second fire and weather resistant
fiberglass-based facer having a length, a width, and a thickness;
the second fiberglass-based facer having first and second major
surfaces that are each defined by the length and the width of the
second fiberglass-based facer; the second fiberglass-based facer
comprising between about 15% and 25% by weight fiberglass mat and
between about 75% and 85% by weight a polymeric based coating
material containing an inorganic filler; the second
fiberglass-based facer being substantially impervious to the
passage of hot gases of combustion through the thickness of the
second fiberglass-based facer; and the second fiberglass-based
facer being substantially coextensive with and bonded to the bottom
major surface of the second board layer; and the polymeric material
or predominantly polymeric foam material of the second board layer
penetrating part of the way through, but not completely through,
the second fiberglass-based facer from the first major surface of
the second fiberglass-based facer to effect a strong bond between
the second fiberglass-based facer and the second board layer while
the second major surface of the second fiberglass-based facer is
free of the polymeric material or predominantly polymeric foam
material of the second board layer.
41. The prefabricated, faced roofing board composite according to
claim 29, including: a second board layer made of a polymeric
material or a predominantly polymeric foam material; the second
board layer having a length, a width, and a thickness; the second
board layer having a top major surface and a bottom major surface
that are each defined by the length and the width of the second
board layer; the second board layer having a density that differs
from and is less than the density of the first board layer; and the
top major surface of the second board layer being substantially
coextensive with and bonded to the bottom major surface of the
first board layer; and a third board layer made of a polymeric
material or a predominantly polymeric material; the third board
layer having a length, a width, and a thickness; the third board
layer having a top major surface and a bottom major surface that
are each defined by the length and the width of the third board
layer; the third board layer having a density that differs from and
is greater than the density of the second board layer; and the top
major surface of the third board layer being substantially
coextensive with and bonded to the bottom major surface of the
second board layer.
42. The prefabricated, faced roofing board composite according to
claim 41, wherein: the polymeric material or predominately
polymeric material of the first board layer has an average density
between 6 lbs/ft.sup.3 and 25 lbs/ft.sup.3; and the first board
layer forms a cover board layer of the prefabricated, faced roofing
board composite; the polymeric material or predominately polymeric
foam material of the second board layer has an average density less
than 6 lbs/ft.sup.3; and the second board layer forms an insulation
board layer of the prefabricated, faced roofing board composite;
and the polymeric material or predominately polymeric material of
the third board layer has an average density between 6 lbs/ft.sup.3
and 25 lbs/ft.sup.3; and the third board layer forms a baseboard
layer of the prefabricated, faced roofing board composite.
43. The prefabricated, faced roofing board composite according to
claim 41, wherein: the polymeric material or predominately
polymeric material of the first and third board layers is a
high-density polyisocyanurate or predominately polyisocyanurate
material; and the polymeric material or predominately polymeric
foam material of the second board layer is a low-density
polyisocyanurate or predominately polyisocyanurate foam
material.
44. The prefabricated, faced roofing board composite according to
claim 41, including: a second fire resistant fiberglass-based facer
having a length, a width, and a thickness; the second
fiberglass-based facer having first and second major surfaces that
are each defined by the length and the width of the second
fiberglass-based facer; the second fiberglass-based facer
comprising between about 15% and 25% by weight fiberglass mat and
between about 75% and 85% by weight a polymeric based coating
material containing an inorganic filler; the second
fiberglass-based facer being substantially impervious to the
passage of hot gases of combustion through the thickness of the
second fiberglass-based facer; and the second fiberglass-based
facer being substantially coextensive with and bonded to the bottom
major surface of the third board layer; and the polymeric material
or predominantly polymeric material of the third board layer
penetrating part of the way through, but not completely through,
the second fiberglass-based facer from the first major surface of
the second fiberglass-based facer to effect a strong bond between
the second fiberglass-based facer and the third board layer while
the second major surface of the second fiberglass-based facer is
free of the polymeric material or predominantly polymeric material
of the third board layer.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. Ser. No.
11/126,583 filed on May 11, 2005, which is hereby incorporated by
reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] The subject invention relates to low-slope roofs that are
typically found on commercial and industrial buildings, and in
particular to an improved fire and moisture resistant
fiberglass-based facer that is impervious or substantially
impervious to the passage of hot gases of combustion, water, and
water vapor through the thickness of the fiberglass-based facer and
to prefabricated faced roofing board composites for use on
low-slope roofs that include one or more polymeric or predominately
polymeric board layers and are faced on at least one major surface
with the fire and moisture resistant fiberglass-based facer of the
subject invention.
[0003] Commercial and industrial buildings typically have roofs
with low-slope roof decks. The roofing systems for these low-slope
roofs typically include one or more layers of a low-density roofing
insulation, a high-density 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. If
not protected, the layer(s) of low-density insulation, such as a
low-density polymer-based foam insulation, can be partially crushed
or otherwise damaged from worker traffic over the insulation, the
placement of heavy objects on the insulation, the weather, and
other causes commonly encountered in roofing construction. The
layer of high-density roofing cover boards that overlies the one or
more layers of low-density insulation, protects the more fragile
low-density insulation from damage, 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
high-density 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 prefabricated faced roofing cover board
composite, an improved prefabricated faced roofing insulation board
composite, and an improved prefabricated faced roofing board
composite that includes at least an insulation board layer and a
roofing cover board layer. With the use of such improved
prefabricated faced roofing board 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.
SUMMARY OF THE INVENTION
[0004] The subject invention provides an improved fire and moisture
resistant fiberglass-based facer and prefabricated faced roofing
board composites that are faced with the improved fiberglass-based
facer. The prefabricated faced roofing board composites of the
subject invention that are faced with the improved fire and
moisture resistant fiberglass-based facer of the subject invention
include: an improved prefabricated faced polymeric or predominately
polymeric roofing cover board composite, an improved prefabricated
faced polymeric or predominately polymeric roofing insulation board
composite, an improved prefabricated faced polymeric or
predominately polymeric roofing board composite that includes at
least an insulation board layer and a roofing cover board layer;
and an improved prefabricated faced polymeric or predominately
polymeric roofing board composite that includes at least two
polymer or predominately polymeric material layers that differ from
each other in density, composition, density and composition, or
otherwise differ from each other in their physical and/or chemical
characteristics. The prefabricated faced roofing board composites
of the subject invention with the improved fire and moisture
resistant fiberglass-based facer of the subject invention exhibit
improved fire retardant properties and reduced flame spread
characteristics.
[0005] The improved fire and moisture resistant fiberglass-based
facer of the subject invention is substantially impervious to the
passage of hot gases of combustion, water, and water vapor through
the thickness of the fiberglass-based facer. Typically, the
polymeric or predominately polymeric materials of polymeric roofing
boards are not very fire resistant and the presence of normal
blowing agents, such as pentane, within the polymeric or
predominately polymeric foam materials of polymeric roofing boards
further degrades the fire resistant properties of such roofing
boards. It is believed that the nonporous nature of the
fiberglass-based facer of the subject invention plus the fire
retardant nature of the fiberglass mat or the fiberglass mat and
mineral fillers of the fiberglass-based facer of the subject
invention causes the fiberglass-based facer of the subject
invention to function as both a fire barrier for the polymeric
roofing board layer(s) of the roofing board composites of the
subject invention and a thermal barrier that reduces the
temperature of the underlying polymeric or predominately polymeric
roofing board layer(s) of the roofing board composites of the
subject invention. Thus, when compared with previous roofing board
composites made of polymeric or predominately polymeric materials
and faced with either paper facers or permeable coated or uncoated
facers, the roofing board composites of the subject invention are
more fire resistant and exhibit improved fire retardant and flame
spread characteristics.
[0006] In a preferred embodiment of the fiberglass-based facer of
the subject invention, the fiberglass-based facer includes a
fiberglass mat with a first major surface which forms a first major
surface of the facer and is adapted to overlay a major surface of a
roofing board and a second major surface which is coated with a
highly inorganic filled latex based coating material
(limestone/latex coating mixture). The highly inorganic filled
latex based coating material combines with the fiberglass mat to
form a fiberglass based facer that is between about 15% and 25% by
weight fiberglass mat and between about 75% and 85% by weight
highly inorganic filled latex based coating material and has a
Gurley porosity of at least 300 (Gurley porosity is the time in
seconds for 100 cubic centimeters of air to pass through one square
inch of a material). Preferably, the fiberglass-based facer of the
subject invention has a structure for permitting a limited
penetration of a polymeric or predominately polymeric material
liquid mixture through the first major surface of the
fiberglass-based facer into, but only part of the way through, the
fiberglass-based facer when the fiberglass-based facer overlies the
polymeric or predominately polymeric material liquid mixture during
the formation of a roofing board from the polymeric or
predominately polymeric material liquid mixture. Thus, a
prefabricated faced roofing board composite is formed having a
strong bond between the fiberglass-based facer and the roofing
board without permitting the polymeric or predominately polymeric
material liquid mixture to pass through the fiberglass-based facer
to the first major surface of the fiberglass facer where the
polymeric or predominately polymeric material liquid mixture could
adversely affect both the manufacturing process and the desired
physical characteristics of the prefabricated faced roofing board
composite.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a schematic perspective view of a fiberglass-based
facer of the subject invention for improving the fire resistance
and weathering properties of a polymeric roofing board.
[0008] FIG. 2 is a schematic perspective view of a prefabricated
faced roofing board composite of the subject invention that
includes a high-density polymer or predominantly polymer material
cover board with a fiberglass-based facer overlying the top major
surface of the cover board.
[0009] FIG. 3 is a schematic perspective view of a prefabricated
faced roofing board composite of the subject invention that
includes a high-density polymer or predominantly polymer material
cover board with a fiberglass-based facer overlying the top major
surface of the cover board and a fiberglass-based or other facer
overlying the bottom major surface of the cover board.
[0010] FIG. 4 is a schematic perspective view of a prefabricated
faced roofing board composite of the subject invention that
includes a low-density polymer or predominantly polymer material
foam insulation board with a fiberglass-based facer overlying the
top major surface of the insulation board.
[0011] FIG. 5 is a schematic perspective view of a prefabricated
faced roofing board composite of the subject invention that
includes a low-density polymer or predominantly polymer material
foam insulation board with a fiberglass-based facer overlying the
top major surface of the insulation board and a fiberglass-based or
other facer overlying the bottom major surface of the insulation
board.
[0012] FIG. 6 is a schematic perspective view of a prefabricated
faced roofing board composite of the subject invention that
includes two polymeric or predominantly polymeric material layers
that differ from each other in density, composition, density and
composition, or otherwise physically and/or chemically differ from
each other (such as a high-density polymer or predominantly polymer
material cover board and a low-density polymer or predominantly
polymer material foam insulation board) with a fiberglass-based
facer overlying the top major surface of the roofing board
composite.
[0013] FIG. 7 is a schematic perspective view of a prefabricated
faced roofing board composite of the subject invention that
includes two polymeric or predominantly polymeric material layers
that differ from each other in density, composition, density and
composition, or otherwise physically and/or chemically differ from
each other (such as a high-density polymer or predominantly polymer
material cover board and a low-density polymer or predominantly
polymer material foam insulation board) with a fiberglass-based
facer overlying the top major surface of the roofing board
composite and a fiberglass-based or other facer overlying the
bottom major surface of the roofing board composite.
[0014] FIG. 8 is a schematic perspective view of a prefabricated
faced roofing board composite of the subject invention that
includes three polymeric or predominantly polymeric material layers
wherein at least two of the layers differ from each other in
density, composition, density and composition, or otherwise
physically and/or chemically differ from each other (such as 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) with a fiberglass-based facer overlying
the top major surface of the roofing board composite.
[0015] FIG. 9 is a schematic perspective view of a prefabricated
faced roofing board composite of the subject invention that
includes three polymeric or predominantly polymeric material layers
wherein at least two of the layers differ from each other in
density, composition, density and composition, or otherwise
physically and/or chemically differ from each other (such as 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) with a fiberglass-based facer overlying
the top major surface of the composite and a fiberglass-based or
other facer overlying the bottom major surface of the
composite.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] FIG. 1 shows a fiberglass-based facer 20 of the subject
invention for improving the fire resistance and weathering
properties of a roofing board or roofing board composite. The fire
and weather resistant fiberglass-based facer 20 has a length, a
width, and a thickness with first and second major surfaces 22 and
24 that are each defined by the length and the width of the
fiberglass-based facer 20. The first major surface 22 of the
fiberglass-based facer 20 is adapted to be bonded to a polymeric or
predominately polymeric roofing board layer to form a roofing board
composite incorporating the fiberglass-based facer 20 and the
second major surface 24 of the fiberglass-based facer 20 is adapted
to form an exposed surface of the roofing board composite.
[0017] The fiberglass-based facer 20 may be: a) a woven or nonwoven
uncoated fiberglass mat alone, b) an uncoated woven or nonwoven
fiberglass mat with a polymeric binder, c) an uncoated woven or
nonwoven fiberglass mat with a polymeric binder containing one or
more mineral fillers, d) an uncoated woven or nonwoven fiberglass
mat with one or more mineral fillers, e) a coated woven or nonwoven
fiberglass mat that is coated with a coating containing one or more
mineral fillers and a mineral filler carrier (e.g. an organic
binder or emulsion) applied to a major surface of the facer that is
to be the exposed major surface of the facer, or f) any of facers a
to d with a coating containing one or more mineral filler(s) and a
mineral filler carrier (e.g. an organic binder or emulsion) applied
to a major surface of the facer that is to be the exposed major
surface of the facer. Preferably, the fiberglass-based facer 20 has
a Gurley porosity of at least 300. In a preferred embodiment of the
fiberglass-based facer 20, the fiberglass-based facer includes a
fiberglass mat with a first major surface which forms the first
major surface 22 of the facer and is adapted to overlay a major
surface of a roofing board and a second major surface which is
coated with a highly inorganic filled latex based coating material
(limestone/latex coating mixture). The highly inorganic filled
latex based coating material combines with the fiberglass mat to
form a fiberglass based facer that is between about 15% and 25% by
weight fiberglass mat and between about 75% and 85% by weight
highly inorganic filled latex based coating material and has a
Gurley porosity of at least 300.
[0018] The fiberglass-based facer 20 is substantially impervious to
the passage of hot gases of combustion, water, and water vapor
through the thickness of the fiberglass-based facer. In addition,
the fiberglass-based facer 20 has a structure for permitting a
limited penetration of a polymeric or predominately polymeric
liquid mixture through the first major surface 22 of the
fiberglass-based facer into, but only part of the way through, the
fiberglass-based facer when the fiberglass-based facer overlies the
polymeric or predominately polymeric liquid mixture during the
formation of a roofing board layer from the polymeric or
predominately polymeric liquid mixture. Thus, a strong bond is
formed between the fiberglass-based facer and the roofing board
layer without permitting the polymeric or predominately polymeric
liquid mixture to pass through the fiberglass-based facer to the
second major surface 24 of the fiberglass-based facer 20.
[0019] Where the fiberglass-based facer is formed by an uncoated
fiberglass mat alone, the glass fibers and/or filaments of the mat
are so entangled and/or closely spaced with respect to each other
that fiberglass mat is substantially impervious to the passage of
hot gases of combustion, water, and water vapor through the
thickness of the fiberglass mat and thus the fiberglass-based facer
20. In preferred embodiments of the fiberglass-based facer 20, the
fiberglass mat may progressively increase in density from the major
surface of the fiberglass mat that forms the first major surface 22
of the fiberglass-based facer 20 to the major surface of the
fiberglass mat that forms the second major surface 24 of the
fiberglass-based facer 20; the fiberglass mat may have a higher
density at and adjacent the major surface of the fiberglass mat
that forms the second major surface 24 of the fiberglass-based
facer 20 than throughout a remainder of the mat thickness; or the
fiberglass mat may have a lower density at and adjacent the major
surface of the fiberglass mat that forms the first major surface 22
of the fiberglass-based facer 20 than throughout a remainder of the
mat thickness. These facer structures facilitate a limited
penetration of a polymeric or predominately polymeric liquid
mixture through the first major surface 22 of the fiberglass-based
facer 20 into, but only part of the way through, the
fiberglass-based facer 20 when the fiberglass-based facer 20
overlies the polymeric or predominately polymeric liquid mixture
during the formation of a roofing board layer from the polymeric or
predominately polymeric liquid mixture. Thus, a strong bond is
formed between the fiberglass-based facer and the roofing board
layer without permitting the polymeric or predominately polymeric
liquid mixture to pass through the fiberglass-based facer to the
second major surface 24 of the fiberglass-based facer 20 where the
polymeric or predominately polymeric liquid mixture could adversely
affect the manufacturing process and/or the physical
characteristics of the resulting faced roofing board composite.
[0020] Where the fiberglass-based facer 20 is formed by an uncoated
fiberglass mat and a polymeric binder, a polymeric binder
containing mineral filler(s), or mineral filler(s), the glass
fibers and/or filaments of the mat are so entangled and/or closely
spaced with respect to each other and the interstices of the
fiberglass mat are so filled with the polymeric binder, the
polymeric binder containing mineral filler(s), or the mineral
fillers that the fiberglass mat with the polymeric binder, the
polymeric binder containing mineral filler(s) or the mineral
filler(s) is substantially impervious to the passage of hot gases
of combustion, water, and water vapor through the thickness of the
fiberglass mat and thus the fiberglass-based facer 20. In preferred
embodiments of the fiberglass-based facer 20, the polymeric binder,
the polymeric binder containing mineral filler(s) or the mineral
filler(s) may be incorporated into the fiberglass mat at and
adjacent the major surface of the fiberglass mat that forms the
second major surface 24 of the fiberglass-based facer 20 rather
than throughout the thickness of the fiberglass mat or the
polymeric binder, the polymeric binder containing mineral filler(s)
or the mineral filler(s) may be incorporated throughout the
thickness of the mat except at and adjacent the major surface of
the fiberglass mat that forms the first major surface 22 of the
fiberglass-based facer 20. This facer structure facilitates the
limited penetration of a polymeric or predominately polymeric
liquid mixture through the first major surface 22 of the
fiberglass-based facer into, but only part of the way through, the
fiberglass-based facer 20 when the fiberglass-based facer 20
overlies the polymeric or predominately polymeric liquid mixture
during the formation of a roofing board layer from the polymeric or
predominately polymeric liquid mixture. Thus, a strong bond is
formed between the fiberglass-based facer and the roofing board
layer without permitting the polymeric or predominately polymeric
liquid mixture to pass through the fiberglass-based facer to the
second major surface 24 of the fiberglass-based facer 20 where the
polymeric or predominately polymeric liquid mixture could adversely
affect the manufacturing process and/or the physical
characteristics of the resulting faced roofing board composite. A
mineral filler such as but not limited to calcium carbonate, mica,
talc, and silica or blends of these mineral fillers may be used as
the mineral filler(s) and the mineral fillers may be bonded to the
fiberglass mat with inorganic adhesive materials. The polymeric
binder, polymeric binder with mineral filler(s) or mineral
filler(s) may be applied by any normal and established application
technique.
[0021] Where the fiberglass-based facer 20 is formed by a
fiberglass mat coated on a major surface with a coating containing
mineral fillers and a mineral filler carrier (e.g. a
limestone/latex coating mixture), the glass fibers and/or filaments
of the mat are so entangled and/or closely spaced with respect to
each other and the interstices of the fiberglass mat are so filled
with the mineral fillers and mineral filler carrier that the
fiberglass mat with the mineral fillers and mineral filler carrier
containing coating is substantially impervious to the passage of
hot combustion gases, water, and water vapor through the thickness
of the fiberglass mat and thus the fiberglass-based facer 20. In
preferred embodiments of the fiberglass-based facer 20, the mineral
filler(s) and mineral filler carrier of the coating may be
incorporated into the fiberglass mat at and adjacent the major
surface of the fiberglass mat that forms the second major surface
24 of the fiberglass-based facer 20 rather than throughout the
thickness of the fiberglass mat or the mineral filler(s) and
mineral filler carrier of the coating may be incorporated
throughout the thickness of the mat except at and adjacent the
major surface of the fiberglass mat that forms the first major
surface 22 of the fiberglass-based facer 20. This facer structure
facilitates the limited penetration of a polymeric or predominately
polymeric liquid mixture through the first major surface 22 of the
fiberglass-based facer into, but only part of the way through, the
fiberglass-based facer 20 when the fiberglass-based facer 20
overlies the polymeric or predominately polymeric liquid mixture
during the formation of a roofing board layer from the polymeric or
predominately polymeric liquid mixture. Thus, a strong bond is
formed between the fiberglass-based facer and the roofing board
layer without permitting the polymeric or predominately polymeric
liquid mixture to pass through the fiberglass-based facer to the
second major surface 24 of the fiberglass-based facer 20 where the
polymeric or predominately polymeric liquid mixture could adversely
affect the manufacturing process and/or the physical
characteristics of the resulting faced roofing board composite. A
mineral filler such as but not limited to calcium carbonate, mica,
talc, and silica or blends of these mineral fillers may be used as
the mineral filler(s) and these filler(s) may be bonded to the
fiberglass mat with inorganic adhesive materials that form or are
included in the mineral filler carrier. The mineral filler carrier
may be formulated to enhance the performance of the
fiberglass-based facer 20 and may include a fire retardant to
further mitigate flammability and smoke generation and/or other
additives, such as but not limited to rheology modifiers and
additives that enhance the UV resistance and/or other weathering
characteristics of the facer. The coating may be applied by any
normal and established application technique, such as but not
limited to drawdown coating, spray coating, roll coating, knife
over roll coating, etc.
[0022] The fiberglass-based facer 20 may be applied to various
single or multi-layer roofing boards to form prefabricated faced
roofing board composites that are more fire and weather resistant.
For example, a fiberglass-based facer 20 can be applied to one
major surface or fiberglass-based facers 20 can be applied to both
major surfaces of a roofing cover board; a fiberglass-based facer
20 can be applied to one major surface or fiberglass-based facers
20 can be applied to both major surfaces of a roofing insulation
board; a fiberglass-based facer 20 can be applied to one major
surface or fiberglass-based facers 20 can be applied to both major
surfaces of high density and low density polymeric or predominately
polymeric material roofing board composite (e.g. a cover board and
insulation board composite or a cover board, insulation board, and
baseboard composite); and a fiberglass-based facer 20 can be
applied to one major surface or fiberglass-based facers 20 can be
applied to both major surfaces of multi-layer polymeric or
predominately polymeric material roofing board composite where at
least two of the polymeric or predominately polymeric material
layers of the composite differ from each other (e.g. have
densities, compositions, or densities and compositions that differ
from each other). In addition, where a fiberglass-based facer 20 is
applied to one major surface of a single or multi-layer roofing
board to form a faced roofing board composite that is more fire and
weather resistant, the other major surface of the roofing board may
be overlaid with a different type of facer, e.g. a
non-fiberglass-based facer or a facer having different physical
characteristics or properties.
[0023] FIG. 2 is a schematic perspective view of a prefabricated
faced roofing board composite 30 of the subject invention. The
prefabricated faced roofing board composite 30 is a faced roofing
cover board composite with a high-density polymer or predominantly
polymer material or foam material core layer 32 and a
fiberglass-based facer 20 overlying and bonded to the top major
surface of the high-density polymer or predominantly polymer
material or foam material core layer 32. The fiberglass-based facer
20 may be substantially coextensive with, coextensive with, or
extend beyond the major surface of the core layer 32 to which the
fiberglass-based facer 20 is bonded along the length(s) of any one,
two, or three edges of the core layer 32 or along the lengths of
all four edges of the core layer 32 to overlap and be bonded to
other roofing cover board composites.
[0024] Preferably, the high-density polymer or predominantly
polymer material or foam material core layer 32 of the faced
roofing cover board composite 30 has a density or an average
density between 6 lbs/ft.sup.3 and 25 lbs/ft.sup.3 and more
preferably a density or an average density of at least 8
lbs/ft.sup.3. Typically, the high-density polymer or predominantly
polymer material or foam core layer 32 of the faced roofing cover
board composite 30 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 faced roofing cover
board composite 30 prior to installation. Preferably, the
high-density polymer or predominantly polymer material or foam
material core layer 32 of the faced roofing cover board composite
30 has a thickness of about 0.08 inches or greater and more
preferably a thickness between about 0.08 inches and about 0.75
inches. The density and thickness of the high-density polymer or
predominantly polymer material or foam material core layer 32 of
the faced roofing cover board composite 30 are selected to provide
the faced roofing cover board composite 30 with the compressive
strength to resist deformation and protect low-density insulation
layers overlaid by the faced roofing cover board composite from
damage. For example, the polymer or predominantly polymer material
core layer 32 may vary in density throughout the thickness of the
core layer with the core layer progressively increasing in density
from its bottom major surface to its top major surface.
[0025] The high-density polymer or predominantly polymer material
or foam material core layer 32 of the faced roofing cover board
composite 30 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 32 is a
high-density polyisocyanurate or predominantly polyisocyanurate
material or foam material. The predominantly polymer materials of
the high-density core layer 32 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 32, 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 polymer material core layer 32 are fillers such as
limestone (CaCO.sub.3), fiberglass, recycled polyisocyanurate dust,
and extenders/plasticizers.
[0026] FIG. 3 is a schematic perspective view of a prefabricated
faced roofing board composite 36 of the subject invention. The
prefabricated faced roofing board composite 36 is a faced roofing
cover board composite with a high-density polymer or predominantly
polymer material or foam material core layer 32 and
fiberglass-based facers 20 overlying and bonded to each major
surface of the high-density polymer or predominantly polymer
material or foam material core layer 32. Either or both of the
fiberglass-based facers 20 may be substantially coextensive with,
coextensive with, or extend beyond the major surface of the core
layer 32 to which the fiberglass-based facer 20 is bonded along the
length(s) of any one, two, or three edges of the core layer 32 or
along the lengths of all four edges of the core layer 32 to overlap
and be bonded to other roofing cover board composites. Other than
having fiberglass-based facers 20 that overlie and are bonded to
both major surfaces of the high-density polymer or predominantly
polymer material or foam material core layer 32, the faced roofing
cover board composite 36 is the same as the faced roofing cover
board composite 30.
[0027] FIG. 4 is a schematic perspective view of a prefabricated
faced roofing board composite 40 of the subject invention. The
prefabricated faced roofing board composite 40 is a faced roofing
insulation board composite with a low-density polymer or
predominantly polymer material foam core layer 42 and a
fiberglass-based facer 20 that overlies and is bonded to the top
major surface of the low-density polymer or predominantly polymer
material foam core layer 42. The fiberglass-based facer 20 may be
substantially coextensive with, coextensive with, or extend beyond
the major surface of the core layer 42 to which the
fiberglass-based facer 20 is bonded along the length(s) of any one,
two, or three edges of the core layer 42 or along the lengths of
all four edges of the core layer 42 to overlap and be bonded to
other roofing insulation board composites 40.
[0028] Preferably, the low-density polymer or predominantly polymer
material foam core layer 42 of the faced roofing insulation board
composite 40 has a density or an average density of less than 6
lbs/ft.sup.3, preferably less than 4 lbs/ft.sup.3, and typically a
density or an average density between about 1 lbs/ft.sup.3 and
about 3 lbs/ft.sup.3. Typically, the low-density polymer or
predominantly polymer material foam core layer 42 of the faced
roofing insulation board composite 40 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 faced roofing insulation board composite 40 prior to
installation. Preferably, the low-density polymer or predominantly
polymer material foam core layer 42 of the faced roofing insulation
board composite 40 has a thickness of about 0.50 inches or greater
and more preferably a thickness between about 0.50 inches and about
6 inches. The density and thickness of the low-density polymer or
predominantly polymer material foam core layer 42 of the faced
roofing insulation board composite 40 are selected to provide the
faced roofing insulation board composite 40 with the desired
insulating properties for the roofing system application. For
example, the polymer or predominantly polymer material core layer
42 may vary in density throughout the thickness of the core layer
with the core layer progressively increasing in density from its
bottom major surface to its top major surface. The low-density
polymer or predominantly polymer material foam core layer 42 of the
faced roofing insulation board 40 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.
[0029] FIG. 5 is a schematic perspective view of a prefabricated
faced roofing board composite 46 of the subject invention. The
prefabricated faced roofing board composite 46 is a faced roofing
insulation board composite with a low-density polymer or
predominantly polymer material foam core layer 42 and
fiberglass-based facers 20 overlying and bonded to each major
surface of the low-density polymer or predominantly polymer
material foam core layer 42. Either or both of the fiberglass-based
facers 20 may be substantially coextensive with, coextensive with,
or extend beyond the major surface of the core layer 42 to which
the fiberglass-based facer 20 is bonded along the length(s) of any
one, two, or three edges of the core layer 42 or along the lengths
of all four edges of the core layer 42 to overlap and be bonded to
other roofing insulation board composites. Other than having
fiberglass-based facers 20 that overlie and are bonded to both
major surfaces of the low-density polymer or predominantly polymer
material foam core layer 42, the faced roofing insulation board
composite 46 is the same as the faced roofing insulation board
composite 40.
[0030] FIG. 6 is a schematic perspective view of a prefabricated
faced roofing board composite 50 of the subject invention. The
prefabricated faced roofing board composite 50 includes a
high-density polymer or predominantly polymer material or foam
material core layer 32, a low-density polymer or predominantly
polymer material foam core layer 42 that are bonded together, and
fiberglass-based facer 20 that overlies and is bonded to a top
major surface of the core layer 32. The fiberglass-based facer 20
may be substantially coextensive with, coextensive with, or extend
beyond the major surface of the core layer 32 to which the
fiberglass-based facer 20 is bonded along the length(s) of any one,
two, or three edges of the core layer 32 or along the lengths of
all four edges of the core layer 32 to overlap and be bonded to
other roofing board composites. The prefabricated faced roofing
board composite 50 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 faced
roofing board composite prior to installation.
[0031] Preferably, the high-density polymer or predominantly
polymer material or foam material core layer 32 of the faced
roofing board composite 50 has a density or an average between 6
lbs/ft.sup.3 and 25 lbs/ft.sup.3 and more preferably a density or
average density of at least 8 lbs/ft.sup.3. Preferably, the
high-density polymer or predominantly polymer material or foam
material core layer 32 of the faced roofing board composite 50 has
a thickness of about 0.08 inches or greater and more preferably a
thickness between about 0.08 inches and about 0.75 inches. The
density and thickness of the high-density polymer or predominantly
polymer material or foam material core layer 32 of the faced
roofing board composite 30 are selected to provide the roofing core
layer 32 with the compressive strength to resist deformation and
protect low-density insulation core layer 42 of the composite that
is overlaid by the core layer 32. The high-density polymer or
predominantly polymer material or foam material core layer 32 of
the faced roofing board composite 50 may be made of the same
high-density polymer or predominantly polymer materials as the core
layer 32 of the faced roofing cover board composite 30.
[0032] Preferably, the low-density polymer or predominantly polymer
material foam core layer 42 of the faced roofing board composite 50
has a density or average density of less than 6 lbs/ft.sup.3,
preferably less than 4 lbs/ft.sup.3, and typically a density or an
average density between about 1 lbs/ft.sup.3 and about 3
lbs/ft.sup.3. Preferably, the low-density polymer or predominantly
polymer material foam core layer 42 of the faced roofing board
composite 50 has a thickness of about 0.50 inches or greater and
more preferably a thickness between about 0.50 inches and about 6
inches. The density and thickness of the low-density polymer or
predominantly polymer material foam core layer 42 of the faced
roofing board composite 50 are selected to provide the faced
roofing board composite 50 with the desired insulating properties
for the roofing system application. The low-density polymer or
predominantly polymer material core layer 42 of the roofing board
composite 50 may be made of the same low-density polymer or
predominantly polymer materials as the core layer 42 of the roofing
insulation board composite 40.
[0033] FIG. 7 is a schematic perspective view of a prefabricated
faced roofing board composite 54 of the subject invention. The
prefabricated faced roofing board composite 54 includes a
high-density polymer or predominantly polymer material or foam
material core layer 32, a low-density polymer or predominantly
polymer material foam core layer 42 that are bonded together, a
fiberglass-based facer 20 that overlies and is bonded to a top
major surface of the core layer 32, and a fiberglass-based facer 20
that overlies and is bonded to a bottom major surface of the core
layer 42. The fiberglass-based facers 20 may be substantially
coextensive with, coextensive with, or extend beyond the major
surface of the core layer 32 or 42 to which the fiberglass-based
facer 20 is bonded along the length(s) of any one, two, or three
edges of the core layer or along the lengths of all four edges of
the core layer to overlap and be bonded to other roofing board
composites. Other than having fiberglass-based facers 20 that
overlie and are bonded to both the top major surface of the core
layer 32 and the bottom major surface of the core layer 42 instead
of just the top major surface of the core layer 32, the faced
roofing board composite 54 is the same as the faced roofing board
composite 50.
[0034] FIG. 8 is a schematic perspective view of a prefabricated
faced roofing board composite 60 of the subject invention. The
prefabricated faced roofing board composite 60 includes: a
high-density polymer or predominantly polymer material or foam
material core layer 32 that forms a cover board layer of the
composite, a low-density polymer or predominantly polymer material
foam core layer 42 that forms an insulation board layer of the
composite, a high-density polymer or predominantly polymer material
or foam material layer 62 that forms a baseboard layer of the
composite, and a fiberglass-based facer 20 that overlies and is
bonded to the top major surface of the core layer 32. The core
layer 42 is intermediate and bonded to both the core layer 32 and
the core layer 62. The fiberglass-based facer 20 may be
substantially coextensive with, coextensive with, or extend beyond
the major surface of the core layer 32 to which the
fiberglass-based facer 20 is bonded along the length(s) of any one,
two, or three edges of the core layer 32 or along the lengths of
all four edges of the core layer 32 to overlap and be bonded to
other roofing board composites. The prefabricated faced roofing
board 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
board composite prior to installation.
[0035] Preferably, the high-density polymer or predominantly
polymer material or foam material core layers 32 and 62 of the
faced roofing board composite 60 have a density or an average
density between 6 lbs/ft.sup.3 and 25 lbs/ft.sup.3 and more
preferably a density or an average density of at least 8
lbs/ft.sup.3. Preferably, the high-density polymer or predominantly
polymer material or foam material core layers 32 and 62 of the
faced roofing board composite 60 each have a thickness of about
0.08 inches or greater and more preferably a thickness between
about 0.08 inches and about 0.75 inches. The density and thickness
of the high-density polymer or predominantly polymer material or
foam material core layers 32 and 62 of the faced roofing board
composite 60 are selected to provide the core layers 32 and 62 with
the compressive strength to resist deformation and protect
low-density insulation core layer 42 of the composite that located
between the core layers 32 and 42. The high-density polymer or
predominantly polymer material or foam material core layers 32 and
62 of the faced roofing board composite 60 may be made of the same
high-density polymer or predominantly polymer materials as the core
layer 32 of the faced roofing cover board composite 30. The
high-density polymer or predominantly polymer material or foam
material core layers 32 and 62 of the faced roofing board composite
60 may have the same or different densities.
[0036] Preferably, the low-density polymer or predominantly polymer
material foam core layer 42 of the faced roofing board composite 60
has a density or an average density of less than 6 lbs/ft.sup.3,
preferably less than 4 lbs/ft.sup.3, and typically a density or an
average density between about 1 lbs/ft.sup.3 and about 3
lbs/ft.sup.3. Preferably, the low-density polymer or predominantly
polymer material foam core layer 42 of the faced roofing board
composite 60 has a thickness of about 0.50 inches or greater and
more preferably a thickness between about 0.50 inches and about 6
inches. The density and thickness of the low-density polymer or
predominantly polymer material foam core layer 42 of the faced
roofing board composite 60 are selected to provide the faced
roofing board composite 60 with the desired insulating properties
for the roofing system application. The low-density polymer or
predominantly polymer material foam core layer 42 of the faced
roofing board composite 60 may be made of the same low-density
polymer or predominantly polymer materials as the core layer 42 of
the faced roofing insulation board composite 40.
[0037] FIG. 9 is a schematic perspective view of a prefabricated
faced roofing board composite 64 of the subject invention. The
prefabricated faced roofing board composite 64 includes: a
high-density polymer or predominantly polymer material or foam
material core layer 32 that forms a cover board layer of the
composite, a low-density polymer or predominantly polymer material
foam core layer 42 that forms an insulation board layer of the
composite, a high-density polymer or predominantly polymer material
or foam material core layer 62 that forms a baseboard layer of the
composite, a fiberglass-based facer 20 that overlies and is bonded
to the top major surface of the core layer 32, and a
fiberglass-based facer 20 that overlies and is bonded to the bottom
major surface of the core layer 62. The core layer 42 is
intermediate and bonded to both the core layer 32 and the core
layer 62. The fiberglass-based facers 20 may be substantially
coextensive with, coextensive with, or extend beyond the major
surfaces of the core layer 32 or 62 to which the fiberglass-based
facer 20 is bonded along the length(s) of any one, two, or three
edges of the core layer or along the lengths of all four edges of
the core layer to overlap and be bonded to other roofing board
composites. Other than having fiberglass-based facers 20 that
overlie and are bonded to both the top major surface of the core
layer 32 and the bottom major surface of the core layer 62 instead
of just the top major surface of the core layer 32, the faced
roofing board composite 64 is the same as the faced roofing board
composite 60.
[0038] 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, any of the fiberglass-based facers
20 of the subject invention may be used as a facer or facers for a
roofing board composite wherein there is only one polymeric or
predominantly polymeric material layer that progressively increases
in density from its bottom major surface to its top major surface
and has an average density between about 1.2 and about 25
lbs/ft.sup.3 e.g. a prefabricated faced roofing board composite
wherein the polymeric or predominantly polymeric material layer
forms a combined cover and insulation board of the faced roofing
board composite. 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.
* * * * *