CA2247602A1 - Composite roofing members having improved dimensional stability and related methods - Google Patents

Abstract

A composite recovery board (10) comprises a foam core (11) selected from the group consisting of polyisocyanurate and polyurethane materials and mixtures thereof; a facer (15), applied to one major surface (13) of the foam core and comprising a sheet selected from the group consisting of polymer materials, reinforced polymer materials, cellulosic materials, paper, aluminum foil and trilaminates thereof, wherein the reinforced polymer material and the cellulosicmaterial are reinforced with a material selected from the group consisting of glass strands, glass fibers, and mixtures thereof; and, gypsum board (14), applied to the opposite major surface (12) of the foam core. A method of reroofing a roof comprises applying composite recovery boards of the present invention to a roofdeck; and, applying a weather protective layer over the recovery boards. A
continuous method of making a composite recovery board comprises 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 predetermined thickness; curing the polymer foam under heat (44) to create the composite board; and cutting the composite board to desired lengths.

Description

CA 02247602 l998-09-l4 COMPOSITE ROOFING MEMBERS HAVING
IMPROVED DIMENS~NAL ÇTABILITY AND I~ TED
METHODS

CROSS REFERENCE TO RE~TED APPLICAT10NS
This applicatioll is a continuation-in~art of Serial No. 08/700,339, f;led September 23, 1996.

TECHNICAI FIELD
This invention relates to a con~posite board suitable for use as an insulation or r~covel~ board within a roof system. Partlicularly, the present invention relates to a c~..po~ile board having improved dimensional stability, especially when I ~os~-lto ~xtre~e environmental conditions including high heat,humidity and moisture.
BACKGROUND OF THE INVE~ITION
Roof construction in a lowt)itch*d roof generally consi~tc of a roof deck, an insulation barrier above the deck, a weather resistar~t layer applied to the insulation layer, and optionally a layer of heat resistant m~erial. The roof deck 20 generally includes ..,at~ria~~ such as wood, ~ypsum, concrele, steel, and tht like.
Above the roof deck, insulation boards are typically applibd to provide thermal insulation and a uniform surface to which the weather protective layer is applied.
The most common insulation boards are made of p~lyisoe~;murate, and lecov~r~
boards are typically made of woodf~bet or extruded polystyrane. Polyisocyanurate25 may be coated with a pr~te~ re facer that can be either rigW or flexible and can be fire or flame-retardant. In a reroofing operation the roof~deck can refer to the exiJt;..g; roof, including the existinl~ in~wlation and weather resistant layer.Insulation or recovery boards, as they are r-f_r. ~J to in reroofing, have been employed where tl e existinS roof is leaking. These boards are generally 30 applied to a built-up roof deck to proYide a uniform surfa¢e when recovering an exi~ti,.~ roof. The most common r~cov~ boards are made of woodfiber or CA 02247602 l998-09-l4 extruded polystyrene. The woodfiber is typicall~ coated with a thin layer of asphaltic makrial on one side, but extruded polyJl~n ene typically does not contain a facer.
To seal the roof from the elements, the in~iulation or recovery boards are 5 typically COVLled with ~farious materials includ;ng molten asphalt, modified bitumen membrane, rubberized asphdt, or an el_jt~ e. :c compos.tion such as EPDM (ethylenepr~pyleAe diene monomer~. Not all sealirlg materials mentioned previously are cornpatible with each type of insulation or JCcQvel ~ board. For example, molten asphalt cannot be used with extruded polystyrene. Correct 10 combinations of sealing material and insulation or recover~ board are known to those skilled in the industry.
Finally, the he~t resistant layer of material, which is generally applied directly to the weather re~istant layert can include gravel, river stone, foanl or a layer of mastic covereJ by gravel and the like.
Applkation of the weather protective layer can be accomplished by a number of means, usually dictated by the type of material employed. For example,sheets of a protective mernbrane can be rolled out over the roof and banded tG8~lher by torching or the use of an adhesive.
Although inexpensive and generally in wide use, woodfiber and 20 polystyrene-conta;ning in~ulation or recove. ~ boar~s are ofb~n ineffective in hot, humid and wet environments. Particullarly, woodfilber boards will disint~,. ale in a wet, humid environment, which is common in a reroof operation. Poly~l~.ene will expand, bow, or distort in similar en~i onmer~s, e ~.~ t'ly when expoçed to the e,~lre.~ heat exp~ ;~ c~l upon raofs in warmer clima1e~.
The pattnt literature does include panels and boards used for roofi.. g operations. Built-up roof constructions and the components thereof, for example,are well-known in the art. With regard to insulation boards, U.S. Pat. No.
5,001,005 teaches a rigid foam board comprising a thernl~cs~lli.,g plastic foam sandwiched b~twe_., two hcers; the facer cornprising glass fllbers, non-glass filler, and non-asphaltic binder. Likewise, U.S. Pat. No. 4,388,366 teaches a laminate insulation board comprising a plasti~ foam core and at least one facer sheet CA 02247602 l998-09-l4 97030141~ 3 forming both a protective layer and a venting me~ans for fluids; the facer sheetcomprising fine glass fibers bonded tagether w;th polyvinyl acetate.
U.S. Pat. No. 5~081,810 is directed toward a building panel comprising a core sandwkhed between two outer skir s. The core is formed from polystyrene or polyurethane and the owter skins can include plywood or other suitable material.
In lieu of plywood, the use of other materials such as gypsum has been recot,~.ized in the art.
U.S. Pat. No. 3,512,819 is directed toward modular building wall panels comprising a foamed-in-place polyure~hane sandwiched b~t~veen inner and outer faces of construction materials, which incJud~ hardboard, g~rpsum, and plywood.
U.S. Pat. No. 3,842,559 is directed tolbard a roof deck construction fabricated from glass-fiber~reinforced ll ypsum. Spec if ically, the roof deck includes a laminate com~,l;J:ng n) a glas~fiber-reinfurc~l gypsum board, (ii) foamed polyisocyanurate, and (iii~ a layer of weather resistant plastk substance.
U.S. Pat. No. 4p37,006 is directed toward composite insulating panel-boards for use in building construction. The panelboard comprises (i) a rigid, gypsum board base panel, (ii) a self-adherent layer of foamed plastic, and (iii)water-vapor resistant, flame-retardant edge sheets cove~ , the side edges of theplastic foam layer.
U.S. Pat. No. 4,052,831 isdirected towardl a panel buildingconstruction, which can be applied to a roofing sylstem~ comprising (i) a rigid board such as gypsum, and ~ii) a layer of foamed plal~tic ;nsulation.
U.S. Pat. No. 4,449,336 is directed toward a roofing structure comprising, from the bott~m up, (i) steel joints, (ii3 metal d-cking, (iii) a layer of 25 fireproof material formed; of pl~t~ . l~ard, (iv) a re~ervoir board such as gypsum, (v) an insulation layer, and (vi) a layer of rubber lamination.
U.S. Pat. No. 5v220,762 is directed toward fibrous mat-faced, water-resistant gypsum boards. ParticularJy, one embodiment teadhes a roof deck systemincluding~ supporting means, (ii) a fibrous mat-faced, water resistant gypsum board overlying the means, and (ii;) an e~t~r;cr finishing material overlying said board. This embodiment can also include an insulating ...aler;al, such as isocyanurate, liandwichel,l l.et~ee.. the supporting nneans and gypsum board. The CA 02247602 l998-09-l4 970~14166 4 fibrous mat comprises glass fibers and synthetic res;n fibers. When a roof deck is contemplated~ the finishing material includes asphalt and r~ ~f;.~b felt preceded by the application of a settable cementitious material over the fibrous mat-faced gypsum board.
Thus, a need still exists for a recover~ board which can be exposed to moisture during installat~n and remain dimensionally stable while wet and duringthe eventual evaporation of the moisture. Use ol; a composite which contains isocyanurate and/or ure~ane foam beh~reen gypsum board and a facer that co~ r;ses a polymer, such as polypropylene, a poly21mide, palymer latexes and the like, reinforced with glass strands or ~lass fibers and optionally a filler material, such as calcium carbonate, clay, mica anJ the lik~, makes the composite of the present invention di,.,e sbl)ally stable and relatively insensitive to moisture in reroofing.

SUMM~RY OF INVENTIOI'~
It is II.er~f~re, an object of the present invention :to provide a relatively i.,.,J~,~,e..si~eca~npositebaard,particularlyforuseinreroc~fing,,thatisdimensionally stable in hot, humid and wet conditions.
It is another object of the present invention to provide a composite board having a facing th~t can withstand application of the weather protective layer onto the roof.
It is still another object of the present imention to provide a co.ll~Josite board that uses a facers selected from the group consisting of polymer materials, cellulosic materials, paper, aluminum foil and trilaminates thereof.
It is still anothet object of the present invention to provide a cv.l",osile board that uses a polyami~lle facing.
It is anather object of the present invention to provide a co.l.posite board that uses gypsum board in lieu of part;culate wood f~ber board.
It is another object of the pr*sent inventi~n to provide a board that uses both a gypsum board and polyamide facer.
It is still another object of th~e present invention to provide a composite board having wfficient integrity to patch or cover the roof.

CA 02247602 l998-09-l4 It is another object of the present invention to provide a composite board providing a good base for subsequent applkation of the final layer or roofcover;..g and, which is compatible with the latter and the respective means of application.
5It is yet anotl.el object of the ~.r~se.lt invention to provide a method for reroofing utilizing CC~ )O~ le board.
It is still another object to provide a luLIl~d for manufacturing composite boards of the present invention.
It is still another object to provide a method of reroofing a roof 10comprising applying composite boards of the pre~ent invention to a roof d¢ck.
At least one or more of th~ foregoing olbjects of the present invention together with the advantages thereof over the laminated and composite materials,whichshallbecomeapparentfromthespecificationthatfollows,areaccc...plisl,ecl by the inventlhn as hereiRafter de~lcr lbed and clairned.
15In general the present invention providles a cornposite recovery board ca n~ . ;s-ng a foam core selected from the group consisting of polyisocyanurate and polyurethane materials and mixtures 11 ereof; a fac~!r appliecl to one major surface of the foam core and c~u~.r; :ng a sheet selected from th~ group cons:.lJng of polymer materials, reinforced polymer materials, cellulosic materials, paper, 20 aluminum foil and trilaminates ll~ f, wherein tl~ reinfor~ed polymer materials and the cellulosic materials are reinforced with a material s3elected from the group cor.j:Jti"e, of glass strand#, glass fibers, and mixtures thereDf; and gypsum board, applied to the o,u,w~ile In4jor surf ce of the foam core.
The present invention also includes a nl_ll.Gd of reroofing a roof 25 c~ .r;s;ng applying cG"~o~ile recov~_ ~ boards to a roof deck, the reco~fe. ~ boards co"~rr;sing a toam core sele_led from tlhe group con~isting Qf ,~,olyiso.~anurate and polyurethane materials and mixtures tl.~o~; and a facer applied to one major surface of the~foam core and comprising a sheet selected fr~m the group co.-~iJt;r.g of polymer materials, reinforced pol~mer materials, cellulosic materials, paper,30 aluminum foil and trilaminates lhereof, wherein th~! reit~f~r~J poJymer materials and the cellubsic materials are reinforced with a material selected from the group c~,;:.ling of glass strand~, glass fiber$, and mixtures thereof, and gypsum board, applied to the opposite major surhce of the foam core; and, apply;ng a weather prcte~ e layer over the recovery boards.
Finally, the imention provides a continuous method of making a co,nposite re~avel y board comprisin~ the steps of feeding ~gypsum board ;nto a 5 laminator assembly; ~,~ili..g a foamable polymer liquid onto the gypsum board;feeding a facer material into the laminator assembly above the foamable polymer liquid; allowhg the polymer liquid to rise between the gypsum board and facer material forming p Dlyn.er foam of a pre-determine~ thickne~ls; curin~ the palymer foam under heat to create the composite board; and cutting the composite board 10 to desired lengths.

ERIEF DESCRIPTION OF THE DRAWINGS
Fi~ 1 is a perspective ~fiew of a composite I oofi--a member in accordance with the pr~.lt invention; and Fig. 2 is a schematic view of apparatus employed to manufacture roofing ,-,e~.,bers of t~e preienl invention.

PREFERRED EMBODIMENT FOR CARRYING OUT THE INVENTION
The pre3enl invention is directed toward a composite board or roofing 20 member that is used to reroof an existing roof. The roofi.~j, member is applied to a roof deck which is sut*tantially flat or low-pitched, and which can be newly constructed, or which is exposed by the removal of old roofing or, which is an existing built up roof in suitable condition for recovel ;ng. Inasmuch as roof decks are known and do not constitute part of the present inv~r~tion, other than as a 25 substrate or hse upon which the roafing members are laid" further detail is not ~l~cess-~y. Althou~h the roofing members can b~ utilized as part of new roof installations, the boards are spec;r; -lly designed for reroof operations.
One cc.~.r..o,. problem in most if not all reroof inslallations is a wet and often somewhat deteriorated roof or substrate. Typically, when a leak is noticed, 30 and certainly when it is deemed necessary to repair, use of the laminate board of the present in~ention provides an inexpensive and facile means of reroofin~, either the aff~ led area or more commonly, the entire roof. Thus, the roofing member 9~03014166 7 must have sufficient integrity to patch or cover the roof; it must be capable ofsealing the leak; it must provide a good base for sutse~u-nt application of the f;nal layer or covering, such a~ an EPDM roofing m~ . an~, andj it must be compatible with the latter and the respective means of application.
In other words, a board placed over the old roof to act as a substrate for the new waterproof membrane will typ;cally t E. ~...e wet. Existing boards made from wood fiber, extruded polystyrene will distort ~Ind/or deleriorate, necessitating further reroofing effort~. Existing baards manufa~tured ftom isocyanurate foams would fare better, excep1 the ~xi~tin~ state of the art has been to utilize facers that 10 also deteriolrate somewhat, which may lead to untimely failure of the board.
E~i~ling facers are often rei,.f/orctd with organic felt matarials, which provide a wicking action lhrough the facer. While such pr~' le..,6 can be minimized by drying the roof before repair, or by waiting for it to dry, this is not often practical.
Other facer m~terials have employed gbss and fiberglass reinforc~."ent 15 ,con,pone"ls bonded together with such materials as ur~a~formaldehyde resins;however, these "all glass" facers as they are so..,~li.,.~s referred, are notorious for a condition known as "sbike through" during the manufacluring ~rocess. When this occurs, the foam can more readily p~ lrale through the facer and reach the lamination equipment, causing it to freeze up as well as creating other 20 manufacturing problems. This weakness has been somewhat attributed to the industries' usage of polymers as bonding agents that are porous to permit venting of gases and vapors. Polyvinyl acetate~ for example is ofter~ utilized as the bonding agent to provide such porosity in facers reil~forceJ with glass.
Theco.~.osil~t~oardaccordingtothepr(.~ntim~ention isbestdescribed 25 with referellce to Fig. 1. Such a board is indicated Senerally by the numeral 10 and comprises a foam core 11 having firdt and second major surfaces, lower face 12 and upper face 13, respectively. Mating with the lower fxe 12 of the foam core is a gypsum board 14, while a sheet of facer material 15, is bonded to the upperface 13. Thecornpc :le boards 10 are generally from about 1 to about 4 inches 30 thick, and can be fabric~lted in various dimensions dep~ding on the intended application. Boards fabricated into sheets 4 feet wide and 8 feet long are best suited for compatibility ;n the buiWing trade.

The foam core 11 can be polyisocyanurate, polyurethane, or mixtures thereof. The bam core is generally of standard pro~uction and generally inaludesthose having an index of about 25Q. Particularly, when pol~ yanurate foam is employed, those having an index above 200 are prefer, eJ; and when urethane is 5 employed, an index above 120 is pr.f~ J. Further, mixed foams can be employed, such as a mixture of polyisocyanurate and urethane. Norninal density of the polyisocyanurate foams is about 2 pounds per cubic foot ~pcf) and about 2pcf for polyurethane foams.
The upper facer 15 can comprise a polymer material, a reinforced 10 polymer material, or a reinforced cellulosic material, as we~l as paper, aluminum foil and trila~inates thereof. Particularly, the polymer material can include pdypropylene,r~ly.l.el-btexes,polyamide~,ormixtureslh_-~of,andthecellulos;c material can include recycled paper, ¢ardboard and the like~
Examples of polyprc~yl~ne/~,olyl..er latex mixtures include latexes selected from the group consistin~ of styrene-butadiene rubber (SBR), polyvinyl chloride and polyvinyl alcohol. Thicknesses of the lacers typically range between about 0.01 and 0.15 inches.
An example of a suitable polyamide facer material is polyamide 6,6 although other polyamides are equally suitable. Th~ thicknes~i of a polyamide facer of the ~,resent imr~,t o n r~nges from about 0.25 mils to abowt 10 mils, preferably from about 0.4 mils to about 8 mils, and most preferably 1r~m about 0.5 mils to about 6 mils.
The polymer material also includes reinforcing materials such as glass ~IrallJs~ glass fibers, or mixtures thereof. Amounts of such reinforcing materials range from about 1 to about 10,000 parts by weight, based upon 100 parts by we;ght of the polymer sele~ted to form the facer. More~reflerably, the reinforcing materials ranlle from about 1 to about 5000 parts b~ weight, based upon 100;parts by weight of the polymer selected to form the facer. Furthennore, the reinforcedpolymer material can optbnally include fillers suchl as clay, mica, talc, I;mestone (calcium carbonate), gyp~um (calcium sulfate), alum;num trihydrate, a,.limo,)~
oxide, cellulate fibers, pltstic polymer fibers, and mixtures tl,ereof. Amounts of CA 02247602 l998-09-l4 such fillers range from about 0 to about 5000 parts by weight, based upon 100 parts by weight of the polymer sele_)~d to form th~ facer.
Cellulosic material can be reinforced with fibergl~ss in conjunction with carbon black ,~s a pi~j., e~lt and small amounts of bindin~ additives can be fo~ eJ
S into flat composites, suitable for use as facer materials. Other facers con".r;sing aluminum foil and trilaminates of aluminum foil, kraft paper and aluminum foil can also be utilized. As an example of a suitable reinfor~eJ cellulosic tomposile, cellulosic (paper) fibers, 83 percent by weight can be comb;ned with glass fibers, 14 ~ ercent by wei~ht; carbon black (pigment) 1 percent b~ weight and, binding 10 agents (e.g, wood rosin, starch, alum and the like) 2 per.!..)t by weight. The carbon and bhding agents are minimal; while the glass can be increased to about 17 percenl by weight, with an attendant dc~r~ in 1he amount of cellulosic fibers.
Thickness of such a facer is about 24 rnils and generally, as the glass fiber conter~l is increased, the facer can be made th;nner.
In lieu of a particle board or wood fiber base, the p;resent invention substitutes a layer of gyp6um board 14, which is adhered to the lower face 12 ofthe foam core. A suitabk board for this purpose is described in U.S. Pat. No.
5,220,762, the subject matter of which is incG.~r~ted herein by refer~.~ce. Suchgypsum board~ are rnanuf~ctured by Georgia-Pacific Corp~ration and sold under 20 their registered trademark, DENS-DECK. Si~nilar gypsum b~lards would be equally suitable for practice of the present inv~ntion. The Advanta~es include lower cost than wood products and, greater resi~;tance to moisture and wet environments, ll.el ~brrr providing vastly better dirnensional stabilit~r.
The facer of the present invention has beell found to impart 25 w~lh~ abilitr and durabillty to compo~ite boards u$ed as roofing substrates with;n a built-up roof. Particularly, the facers of the present ;nvention have been found to provide dimensional stability to the b oards, inhibiting the boards from distorting under high heat and moisture. In addition to dimensional stability, the hcer pr~te ts the foam from moisture, as well as from penetratlon. Because of these 30 advantages, the facers of the present invention havt been found to be particularly useful with recovel ~ boards becau e the ~ ;.o.".~nt commonlr encountered in CA 02247602 l998-09-l4 9703014166 ' 10 a reroof o~,er~liol. is hot, humid and often wet. Mcreover, the optional fillers add ~lf~nE;II. to the facer and provide the facer with a rugged appearance.
One advantage of the present invention, for example, is that the lamination ot polyisocyanurate foarn one side of a t)ens-Dq~Jc type facer improves 5 the water absorption of t'he Dens~Deck "~t~l;al. Pursuant to a standard water absorption prDtocol (ASTM C-209), after two hours of water cu~.. er ~cn Dens-Deck ~1/4n) alone àksorbc~l 3.28 vol.% water and a stanclard 2" polyisocyanurate foamwlth two celblllosic fibro~s glass mat facers absorbed 0.90 ~ol.% water. For a 2"
composite board consisting of a 2" pDlris~L~anurate foam and a Dens-Deck [1/4") facer, I.o~J.r, the water absort,libn ~,vas only 0.33 vol.% water.
Furthermore, the addition of a polyamide 6,6 far~r opposite the Dens-Deck facer further decr~-~erl the water absorpti~n of the composite. Using a modified ASTM C-209 protocol - where the water a~-or~,tion is measured by vvtYo rather than b~y vol.% - a pDlyisocyanurate foam with a celluh~sic fibrous glass mat facer opposite a Dens-D~ck facer absorbed 50.~ wt.% water. In colltra~l~ a polyamide 6,6 facer coupled with the Dens~Deck facer only absorl,ed 0.9 wt.%
water.
Other advanta~es of boards having both a poly~unide 6,6 facer and a Dens-Deck fxer are hi~h heat stabilllty, d~-.c-~ed foam density, and high load capacity. These boards are stable for ~everal minutes at temperatures up to about 500 ~F, exceeding the range of temperatures that can be; expected for roofs or walls to encounter under normal use con~itions. Furthern~ore, polyamide 6,6, which is heat ;stable to 510~F, is well ~uited to the continuoqls lamination process of the present invention.
Due to better flow, the laminatbn of foam to Dens-Deck, results in a 2.5% reduction in the density of the foam. In add;t;on, a Dens-Deck type facer is less susc.,,lil~le to delamination under load. The bond of polyisocyanurate foamto Dens-Deck (23 psi) is alpproxim~tely twice that of polyi~ocyanurate foam to astandard cell~illosic fibrous glass mat f~cer ~13 psi). Consequently, loads of 40 psi can be exerted on the bo~rd without ~Iffecting the perf~. .,t~nce of the board.
The ccn.~Josite~ boards 10 are typically applied to the roof deck in staggered parallel adjac~nt counes that abut one another. The boards are CA 02247602 l998-09-l4 generally f~ ned to the deck via nails or an adhesive, a~though other means of securing insulation board~to roof deck are common in the arL Once the co.,~o~ileor recovery board of the present invention has been applied to a roof deck, the roof is completed by cov~r;ng the substrate with a weather prot~ rc layer. The 5 prot~lhre layer can inlclude asphalt, bitumen, atactic pol~r~ylene (APP) modified bitumen, rubb~rized asphaJt, EPDM rcolir.g men!~branes or any other conventional prot~ lh~e layer known in the art. In ballast~ roofs, this prvlL li~e layer is then COV&. eJ with gravel or river stone; ~ herein the weight of the river stone serves a second function which is to secure Ihe protL~ e layer to the roof1 0 deck.
While the boards may be m~nufactured in a batch process, a co.,l;.l ~ous, on-line process is preferred as such a ,~rocesj is both effkient and econo..lical.
With reference to Fig. 2, a continuous process is sch¢r~atically d¢picted in conjunction with apparatus 20. The apparatus provides a laminator assembly, generally 21 which employs continuous beilts or treads, 24 ;and 25, reeved around a series of rolls 26, several of which ate driven. Facer material 15 is carried by an upper spool 28 which is positioned for feeding intothe lamin;~itor assembly 21. The gypsum boards 14 are first fed onto the lower belt 25, which is longer than upper belt 24 in order to rece;v~ the boards 14.
Imnlediately above a board 14 as it enters the drive assembly 21, is a foam mixhead 30. The n~xhead 30 is fed from reservoirs 31i and 32, or whatever number are required by the polymer foam co.,~o~it;on selected. Where the desired foam is a polyurethane, for instance, reservoir 31 can ,urovid~ the isocyanate components and reservoir 32 the polyol components. The resin materials from these resqrvoirs are fed through metering ~umps 33 and 34 and through appropriate conduits 35 into the mixhead 30, where upon conbct, reaction commences to form the ~ "er foam.
The ",;~h--d 3~ then supplies an appropriate mixture 36 of resins from the reservoirs 31 ~nd 32, as well as arl appropriately metered amount, onto the surface of the moving board 14. Sutisequently, and slightl~ downstream of the mixhead 30, the facer 15 is fed into the drive assembly 21,i passing around a feed roller 38, whkh r o~ lio,~ the facer 15 against the wpper belt 24. As the board 14, CA 02247602 l998-09-l4 970301~166 1 2 facer 15 and deposiled foamable c~n-~Josilion are conveyed, the latter rises, asdepicted at 40, until the facer 15 is in complete contact with the upper belt 24. It is to be appreciated that the belts 24 and 25 are ~djustable to accommodate the desired thi~ sses of board 10.
After the foaming has completed, the intermedi~te product, indicated by the numeral 42, is heated to effect curing of the polymqr. This is accomplished by appropriately located heaters, ~enerally 44, or by passage through an ov¢n (not shown). After heating for the appropriate time (residence)~and temperature, the product e.n~ljes from the laminator and is cut to length to produce the boards 10.
10 Such cutting is within the skill of the art, including flying cut off saws and the like, which provide desired dimen~ ons without interruption of tl~ apparatus 20. Whilelengths can be varied at will on such apparatus, the widths of the boards 10 cans~Jhse~l ~ntly be lr;mllleJ to size in a separate op(!rdt;o~ T ne~ess~ry. It is also possible to provide sidewalls (not shown) in conJunction with the drive assernbly 15 21, to define the desired widths a~ the rDI~1. ~- is foaming within the Itminator.
Thus it should be evident that the dev;ce and m~thods of the present invention are highly effective in providinlpco..\,~liite boarJ~ useful for reroofing.
The invention is particuhrly suited for reroofing, but is not ~.ecessarily limited thereto. The method of the present invention for manufacturing can be practiced 20 with other equipment and, the metl~d for reroofing can be practiced with the variety of bo~rds 10 that fall within the scope of the pres~* invention.
Based upon the foregoing disclo~iure, it should now be apparent that the use of the ca nposite boards descriW herein will carry ou~ the objects set forthhereinabove. It is, ll.er~.~ore, to be understood tlhat any ~lariations ~J;d~..l fall 25 within the scope of the claimed invention and lhus, the selestion of specific,co"~pc ~ent elements can be determined without departing from the spirit of theinvention herein discl~sed and de~sribed. In partkulat, bDards accordling to thepresent invention are not necessarily limited to those ha~ng an isocyanurate or polyurethane foam core. Moreova, a~s noted hereinabove, dle com~ositi~.~ of the 30 polymer facer can be vari~d, particularly with the use of the optional fillers. Thus, the scope of the invention shall inclu~lle all modifications and variat;ons that may fall within tht scope of the attached claims.

Claims (20)

1. A composite recovery board comprising:
a foam core selected from the group consisting of polyisocyanurate and 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, 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 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 optionally 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 polymer materials are selected from the group consisting of polypropylene, polyamides, polymer latexes, and mixtures thereof.

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 and polyurethane materials and mixtures thereof; and a facer applied to one major surface of said foam core and comprising a sheet selected from the group consisting of polymer materials, 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;
gypsum board, applied to the opposite major surface of said foam core; and applying a weather protective layer over said recovery boards.

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 optionally 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, as set forth in claim 9, wherein said polymer materials are selected from the group consisting of polypropylene, polyamides, polymer latexes, and mixtures thereof.

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 continuous method of making a composite recovery board comprising the steps of:
feeding gypsum board into a laminator assembly;
depositing a foamable polymer liquid onto said gypsum board;

feeding a facer material into said laminator assembly above said foamable polymer liquid;
allowing said polymer liquid to rise between said gypsum board and facer material forming polymer foam of a predetermined thickness;
curing said polymer foam under heat to create said composite board;
and cutting said composite board to desired lengths.

18. A method, as set forth in claim 17, wherein said facer material comprises a sheet selected from the group consisting of polymer materials, reinforced polymer materials, cellulosic materials, paper, aluminum foil and trilaminates thereof, wherein said latter polymer materials and said cellulosic materials are reinforced with a reinforcing material selected from the group consisting of glass strands, glass fibers, and mixtures thereof.

19. A method, as set forth in claim 18, wherein said polymer materials are selected from the group consisting of polypropylene, polyamides, polymer latexes, and mixtures thereof.

20. A method of reroofing a roof, as set forth in claim 18, wherein said sheets optionally 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.