MXPA97006921A

MXPA97006921A - Polyisocianurate boards with reduced moisture absorbance and less air permeability and related methods

Info

Publication number: MXPA97006921A
Application number: MXPA/A/1997/006921A
Authority: MX
Inventors: B Letts John
Original assignee: Bridgestone/Firestone Inc
Priority date: 1996-10-08
Filing date: 1997-09-11
Publication date: 1998-04-01

Abstract

The present invention relates to a composite iso board (10) comprising a foam core (11) selected from the group consisting of polyisocyanurate and polyurethane materials and mixtures thereof, and first and second coatings (12, 13) between which the foam core is walled, the coatings comprise a sheet selected from the group consisting of polyamides and polycarbonates. A method for replacing a roof comprises applying iso boards composed of the present invention to a roof platform, and applying a weather protection layer on the iso boards. The continuous method of producing a composite insulating board iso comprises the steps of feeding a first layer of coating material in a laminator (24), depositing a foamable liquid polymer on the first layer (12), feeding a second layer of the coating material 8139 to the laminator on the foamable liquid polymer, allowing the liquid polymer to grow between the first and second coating materials, forming the polymer foam (42) of a predetermined thickness, curing the polymer foam under heat to create the iso board, cut the iso board into desired stretches and stack in beams the tabler

Description

POLYISOCIANÍRATO BOARDS WITH REDUCED ABSORBANCE DB HUMIDITY AND LESS AIR PERMEABILITY AND RELATED METHODS TECHNICAL FIELD This invention relates to polyisocyanurate boards suitable for use as insulation or as a recovery board within a roofing system, as well as insulating boards in walls. Particularly, the present invention relates to a polyisocyanurate board having reduced moisture absorption and air permeability which, in turn, provide improved dimensional stability and R value. BACKGROUND OF THE INVENTION The construction of ceilings in a low inclination roof, It generally consists of a roof platform, an insulation barrier on the platform, a weather resistant layer applied to the insulation layer and optionally a layer of heat-resistant material. The roof platform generally includes materials such as wood, plaster, concrete, steel and the like. On the roof deck, insulating boards are typically applied to provide thermal insulation and a uniform surface to which the protective layer is applied outdoors. Recovery boards are usually applied to a roof platform, built to provide a uniform surface when an existing roof is recovered. The existing roof is typically hot and humid, and the environmental conditions in which the roofing reinstallation process is carried out are typically hot, humid and hygroscopic. The most common recovery boards are made of wood fibers or extruded polystyrene. Wood fibers are typically coated with a thin layer of asphalt material on the one hand and those recovery boards that are made of polystyrene typically do not contain a coating. While insulating boards are typically not affected by environmental conditions during the construction of a new roof, hot and humid conditions encountered during situations of re-roofing can twist the coatings of many recovery boards. To seal the roof against the elements, the recovery boards are typically covered with various materials including molten asphalt, modified tar membrane, rubberized asphalt or an elastomeric composition such as EPDM (ethylene propylene diene monomer). However, not all seal materials are compatible with each type of recovery board. For example, molten asphalt with extruded polystyrene can not be used. The correct combinations of seal material and recovery board are known to those skilled in the art. The heat-resistant layer of the material, which is generally applied directly to the weather-resistant layer, may include gravel, river stones, foam or a layer of mastic followed by granules. The application of the protective layer outdoors can be achieved by a number of means, usually dictated by the type of material used. For example, sheets of a protective membrane can be unwound on the roof and joined together by blowpipe or by the use of an adhesive. Although economical and generally widely used, insulation containing wood and polystyrene fibers or recovery boards is often ineffective in humid, hygroscopic environments common in a roof replacement operation. Polystyrene will expand, twist or distort in similar environments, especially when exposed to the extreme heat experienced in roofs of hotter climates. The patent literature includes panels and boards used for roofing operations. Constructed roof constructions and their components, for example, are well known in the art as generally explained by Blanpied in US Pat. No. 5,001,005, Dybsky et al., In U.S. Pat. No. 4,944,818 and Rosato et al. In U.S. Pat. No. 4,388,366. With respect to insulating boards, Blanpied illustrates a rigid foam board comprising a thermoset plastic foam sandwiched between two linings; the coating comprises glass fibers, non-glass filler, and non-asphalt binder.

Similarly, Dybsky et al. Illustrates a composite ceiling substrate panel comprising a core of combustible material such as fibers or foams and a coating of non-combustible material such as glass fibers coated with a bituminous material. Rosato et al. Illustrates a laminated insulation board comprising a core of plastic foam and at least one facing sheet which forms both a protective layer and a means of ventilation for fluids; the coating sheet comprises fine glass fibers bonded together with polyvinyl acetate. All existing polyisocyanurate boards or iso boards, as they are sometimes known, use coatings on both sides parallel with the larger surface areas. A coating usually consists of a compound with paper, fiberglass and various binders and additives. The standard coating is an approximate composition of 80 percent by weight of recycled paper, 15 percent by weight of glass fibers and 5 percent by weight of additives and binders. These glass fiber coatings in fact contain a minimum of glass fiber as reinforcement for the coating or sheet material. The high paper content of this coating produces a coating that readily absorbs water, which is not convenient on a polyisocyanurate insulation board. These standard coatings typically absorb as much as 60 percent by weight of water in accordance with ASTM C209. Additionally, these standard coatings are very permeable to gases such as oxygen subsequent to foaming of polyisocyanurate, which decreases the insulating or R-value properties of the iso board. For example, it has been shown that many hundreds and probably thousands of cubic centimeters per hundreds of square centimeters of oxygen can permeate a standard coating in 24 hours in accordance with ASTM D3985. In this way, there is a need for an iso board that is stable through the manufacturing process and more resistant to moisture. The use of a compound containing isocyanurate and / or urethane foam between coatings comprising a polymer, such as polyamide 6.6, optionally reinforced with glass strands or glass fibers and optionally filler material such as calcium carbonate, clay , mica and the like, and optionally various dyes or pigments, make the iso board of the present invention dimensionally stable, relatively insensitive to moisture in replenishment of ceilings and with reduced air permeability, which improves the R value. COMPENDIUM OF THE INVENTION Thus, it is an object of the present invention to provide a relatively inexpensive iso board, with improved physical properties, which is dimensionally stable under humid, hygroscopic and hot conditions.

Another object of the present invention is to provide a composite iso board with coatings comprising a plastic that provides advantages over existing paper / fiberglass coatings. Still another object of the present invention is to provide an iso board with plastic coatings that provides improved insulating properties in ceilings and walls. Still another object of the present invention is to provide a composite iso board that can withstand the heat produced during manufacturing. Still another object of the present invention is to provide an iso board with plastic coatings that reduce the air permeability of the board. Yet another object of the present invention is to provide an isp board with plastic coatings that inhibit gas evolution subsequent to foaming and thus provides improved insulation properties. Still another object of the present invention is to provide a method for replenishing roofs using an iso board according to the present invention. Still another object of the present invention is to provide a method for manufacturing iso boards of the present invention.

At least one or more of the above objects of the present invention together with their advantages over existing iso boards, which will be apparent from the specification that follows, are achieved by the invention as described and claimed below. In general, the present invention provides a composite iso board comprising a foam core selected from the group consisting of polyisocyanurate and polyurethane materials and mixtures thereof; and first and second coatings, between which the foam core is walled, the coatings comprise a sheet selected from the group consisting of polyamides and polycarbonates. The present invention also includes a method for replenishing a roof, comprising applying iso-composite boards to a roof deck, the iso-boards comprising a foam core selected from the group consisting of polyisocyanurate and polyurethane materials and mixtures thereof; and first and second coatings, between which the foam core is walled, the coatings comprise a polymer selected from the group consisting of polyamides and polycarbonates; and apply a protective layer to the weather on the iso boards. Finally, the invention provides a continuous method for producing a composite iso board comprising the steps of feeding a first layer of coating material in a laminator; depositing a foamable liquid polymer on the first layer; feeding a second layer of coating material onto the laminator above the foamable liquid polymer; allowing the liquid polymer to rise between the first and second coating materials to form polymer foam of a predetermined thickness; cure the polymer foam with heat to create the iso board; cut the insulation board in desired sections; and stack them in bundles. BRIEF DESCRIPTION OF THE DRAWINGS Figure i is a perspective view of an iso board composed in accordance with the present invention; and Figure 2 is a schematic view of the apparatus used to fabricate the iso insulation composite board of the present invention. PREFERRED MODALITY FOR CARRYING OUT THE INVENTION The present invention is directed to a composite iso board, which is used in new roofs or to replace an existing roof. The roofing member is applied to a roof platform that is substantially flat or of low inclination and that can be newly built, or that is exposed when the old roof is removed, or that is an existing roof system in suitable conditions for recovery. Since roof platforms are known and do not constitute part of the present invention, apart from as a base substrate on which the roof members are placed, no further details are necessary. In addition, the composite iso board can be used as an insulation board in walls. A common problem in most, if not all, installations for roof replacement is a substrate or roof that is damp and often somewhat deteriorated. Typically, when a leak is noted and safely when it is deemed necessary to repair, the use of the iso board of the present invention provides an economical and easy means of re-roofing either the affected area or most commonly the entire roof. In this way, the roofing member must have sufficient integrity to patch or cover the roof; it should provide a good basis for subsequent application of the final layer or cover, such as an EPDM roofing membrane; and must be compatible with the latter and the respective means of application. Additionally, the roofing member should conveniently possess decreased air permeability, improved insulation values and increased moisture resistance. In other words, a board placed on the old roof to act as a substrate for the new waterproof membrane will typically become wet. Existing boards made from wood fibers, extruded polystyrene will distort and / or deteriorate, requiring greater re-roofing efforts. Existing boards made from isosianurate foams will work better, except that in the state of the art they have been used to use paper coatings that can absorb moisture, causing untimely board failure in certain situations where moisture is present. Existing coatings containing organic felt materials provide an absorption action by capillarity through the coating. While these problems can be minimized by drying the roof before repair, or by waiting for it to dry, this is often not practical. Other coating materials have used glass reinforcement and glass fibers with a urea / formaldehyde resin as binder; however, these "all-glass" coatings, as they are sometimes referred to, are notorious for a condition known as "penetration of the leaf causing a spot on the opposite side" (stríke through) during the manufacturing process. When this happens, the foam can penetrate more easily through the coating and reach the laminating equipment, causing it to freeze as well as creating other manufacturing problems. This weakness has been attributed to some extent to the use of the polymer industry as binding agents that are porous to allow venting of gas and vapors. Polyvinyl acetate, for example, is often used as the binding agent to provide said porosity in glass reinforced coatings. In addition, the polymer sheet material contributes little to resist the influx of air or the emission of blowing agents into the foam; therefore, air permeability is increased which has a deleterious effect on the insulating properties, i.e. R value decreased. The iso board according to the present invention is better described with reference to Figure 1. The board is generally indicated by the number 10 and comprises a core of foam 11 sandwiched between a lower covering 12 and an upper covering 13. The boards 10, when used for recovery applications, are generally approximately 1.27 to 10.16 cm ( .5 to 4"), more preferably approximately 1.27 to 3.81 cm (.5 to 1.5") in thickness and in particular approximately 1.27 to 2.54 cm (.5 to 1") in thickness and can be manufactured in various dimensions depending on the Also, when the boards are used as insulation, the thickness is in the range of approximately 1.27 to 10.16 cm (.5 to 4") in thickness, depending on the insulation value required. Boards manufactured in sheets with 1.22 (4 feet) wide and 2.44 meters (8 feet) long are best suited for compatibility in the construction industry, to replace ceilings or walls. The foam core ll may be polyisocyanurate, urethane or mixtures thereof. The foam core in general is of standard production and generally includes those that have an approximate index of 250. In particular, when polyisocyanurate foam is employed, those having an index above 200 are preferred; and when urethane is employed, an index above 120 is preferred. In addition, mixed foams such as a mixture of polyisocyanurate and urethane can be employed. The lower coating 12 and upper coating 13 of the present invention comprise a thermally stable plastic at temperatures of about 149 ° C (300 ° F). The coatings of this invention do not melt at those temperatures, although some minor wrinkling may occur. The top and bottom coatings of the present invention comprise polymer material, which is formed as a polymer sheet. Particularly, the plastic polymer material can include a polyamide, preferably polyamide 6.6. The polyamide 6, 6 or poly (imi? Oadipoyl-iminohexamethylene), is the condensation product of hexandioic acid and 1,6-diaminohexane. Typical examples of polyamide 6,6 films that can be used are C-917, a molded film; T404A, a film oriented; SF502 and C302, corona treated and thermally treated films, all available from Dupont Canada, Inc. Typically the thicknesses of the coatings are between about .00127 to about .127 cm (.0005 and .05 inch (.5 and. 50 mils)). Although polyamide 6,6 and its analogs are preferred, other polyamides such as polyamide 6, or poly (imino (l-oxohexamethylene)), which is a polymer of caprolactam, may be employed. It will be appreciated that polyamide 6,6 is preferred because it is thermally more stable than polyamide 6. Other examples of polyamides include polyamide II, [poly (imino (l-oxoundecamethylene))], polyamide 12, [poly (imino (1) -oxododecametlleno))] and polyamide 6, 10, [poly (iminohexamethylene-iminosebacoil).] Any polyamides that meet the requirements of thermal stability at 149 ° C (300 ° F) and moisture resistance no worse than about 80 percent polyamide 6.6 can be used. Absolutely not required, the low air permeability in the order of polyamide 6.6 is very convenient.In the case of polyamides such as polyamide 6.6, the carbon bonds between the diamine R * groups can vary and the bonds of The carbon between the dicarboxylic acid groups Ra may vary.The carbon bonds R1 and R2 may include but are not limited to (CH2) 2 a. {CH2) 14 and its isomers. In general, aromatic carbon bonds will not be as thermally stable, especially if they are adjacent to the amine or carboxylic acid groups. A bond of two carbons, group (CH2CH2) between the aromatic group and the amine or carboxylic acid group, is convenient. In the case of polyamides such as polyamide 6, where the amine and the sarboxylic acid are in the same molecule, the R3 carbon bonds may vary from <; CH2h a (CH2) l2 and its isomers. In all these cases, the previous requirements of thermal stability at 149 ° C (300 ° F) and moisture resistance are needed. In addition, polycarbonates such as poly (4,4-isopropylidene diphenylene carbonate) can also be used in place of polyamides although they are not as strong as polyamides and adhesion to urethane foams is not as convenient. Other polymers can be added to modify or adjust the performance of polyamide and polycarbonate polymers such as their thermal stability. The polymer material may also include reinforcing materials such as glass strands, glass fibers or mixtures thereof. Amounts of these reinforcing materials are in the range from about 100 to 10,000 parts by weight, based on 100 parts by weight of the selected polyamide polymer to form the coating. In addition, the reinforced polymer material may optionally include fillers such as clay, mica, talc, limestone (calcium carbonate), gypsum (calcium sulfate), aluminum trihydrate, antimony oxide, cellulose fibers, plastic polymer fibers and its mixtures. Amounts of these fillers are in the range from about 0 to about 5,000 parts by weight, based on 100 parts by weight of the selected polymer to form the coating. Dyes or pigments may also be added at the appropriate level to render the film opaque or aesthetically pleasing. A person with skill in the specialty, easily, without undue experimentation, can determine these levels.

It has been found that the coatings of the present invention impart weather resistance and durability to iso boards employed as roofing substrates within a roof system. Particularly, it has been found that the coatings of the present invention provide dimensional stability to the boards, inhibiting the boards from distorting with high heat and humidity. In addition to dimensional stability, the coatings protect the foam against moisture as well as against physical penetration. Because of these advantages, the use of polyamide coatings has been found particularly beneficial with recovery boards, because the environment commonly found in a roof replacement operation is hot, humid and often hygroscopic. Furthermore, the optional fillings contribute resistance to the coating and provide the coating with a tough appearance. Iso 10 boards typically are applied to the roof deck in adjacent parallel stepped sections that border each other. The boards are generally fastened to the platform by nails or adhesive, although other means for attaching an insulation board to the roof platform are common in the art. Once the iso board of the present invention has been applied to a roof platform, the roof is completed by covering the substrate with a weather protection layer. The protective layer may include any system such as various types of modified asphalt, or EPDM roofing membranes, or any other suitable protective layers known in the art. In ballasted roofs, this protective layer is then covered with gravel, river stones or their mixtures; where the weight of the river stones serves a second function which is to ensure the protective layer and the underlying materials such as recovery boards, to the roof platform. While boards can be manufactured in a batch process, a continuous online process, it is preferred that this process be both efficient and economical. With reference to Figure 2, a continuous process is illustrated schematically in conjunction with the apparatus 20. The apparatus provides upper and lower spools 21 and 22, respectively, for lower and upper polyamide coatings 12 and 13, which are placed to feed in a restricted lift laminator, generally 24, comprising lower and upper continuous belts or belts 25 and 26, wound around a series of rollers 28, several of which are directed. The lower polyamide or bottom 12 coating is first fed to the laminator 24, resting on the belt 25. Immediately on the cover 12, as it enters the laminator 24, a foam mixing head 30 is found. The mixing head 30 is feeds from tanks 31 and 32 or any amount that is required by the selected polymer foam composition. Typically, there are two mixing heads per laminator. When the desired foam is a polyurethane, for example, the reservoir 31 can provide the isocyanate components and the reservoir 32 the polyol components. The resin material of these deposits is fed through metering pumps 33 and 34 and through appropriate conduits 35 to the mixing head 30, where upon contacting, the reaction begins to form the polymer foam. The mixing head 30 then supplies an appropriate mixture 36 of resins from the reservoirs 31 and 32, as well as an amount dosed appropriately on the surface of the moving coating 12. Subsequently, and a little downstream of the mixing head 30, the Upper polyamide coating 13 is fed to the laminator 24, passing around a feed roll 38, which places the coating 13 against the upper band 26. As the polyamide coatings and the foamable composition deposited in the cream state are transported, this last one grows, as illustrated at 40, until the upper covering 13 is in full contact with the upper band 26. It will be appreciated that the bands 25 and 26 are adjustable to allow the desired thicknesses of the board 10. During foaming, the temperature inside the laminator is controlled between 38 ° C and 93 ° C (100 ° F and 200 ° F), so that the intermediate product indicated by the number 42, is cured, this is achieved by appropriately located heaters, generally 44, or by passage through an oven (not shown). After heating the appropriate time (residence) and temperature, the product emerges from the laminator and is cut to length to produce the boards 10. This cut is within the skill of the specialty, including aerial cutting saws and the like, which provide the desired dimensions without interrupting the apparatus 20. While sections may be varied at will in this apparatus, the widths of the boards 10 may be subsequently trimmed to size in a separate operation, as necessary. It is also possible to provide side walls (not shown) in conjunction with the laminator 24, to define the desired widths according to the foam polymer within the conveyor-laminator. In a typical manufacturing operation, iso boards are then stacked to cool and continue to cure. During this process, they are stacked at an approximate height of 1.22 meters. { 4 feet). To date, this stack of boards employing plastic coatings had and verified and controlled carefully, such as by providing a spacer between adjacent boards, because while they are stacked, the internal heat is increased to about 149 ° C (300 ° F) which essentially causes the boards to merge with each other. By the use of the polyamide coatings, according to the present invention, these temperatures do not have an adverse effect on the boards in their stacked position. Still further, the use of polyamide coatings such as polyamide 6.6, provides the additional advantage of minimizing the air influx or emissions, that is, the release of the blowing agents employed in foaming. Because the polyamide 6,6 coatings have very low permeability to the passage of blowing agents and air as an example (9 x 10"13 cm3 (cm) / (sec) / (cm2) {cm. Hg)) for air, iso boards have an improved insulation value, generally a decrease in R value from 1.5 percent between 25 and 50 days, while for conventional boards that have paper coatings / fiberglass, the values R decreases approximately 4 percent in the same time period Low water absorption (less than 0.25 percent by volume, according to ASTM C-209) also characterizes these coatings and improves that property of the iso board EXAMPLES to demonstrate the practice of the present invention, polyisocyanurate boards were produced in a commercial laminator using three different polyamide 6,6 films from Dupont Canada Inc. Polyamide 6,6 plastic films were C-917 (molded), C -203, and SF502, all of which underwent corona treatment. The restricted lift laminator was adjusted for a 5.08 cm (2 in) thick product. The boards were cut into pieces of 1.22 m X 2.44 m X 5.08 cm (4 feet x 8 feet x 2") The formulation used for all three types of polyamide film 6.6 is set forth in Table I. TABLE I COMPOSITION PE BOARD DB INSULATION WEIGHTED PARTS Poliol Poliol, Terate 230L 100.00 HCFC-141b 23.1 HCFC-22 3.10 Water 0.40 Silicone Surfactant, OSi L-5110 1.25 Potassium Octate, OMG 977 2.46 Pentamethylethylenetriamine, Air Products Polycat 5 0.32 Polymeric Diisocyanate Diphenylmethane 155.0 Various physical tests were performed on the previous boards with the three types of Polyamide coatings. The tests, as well as their results, are shown in Table II below.

TABLE II PHYSICAL PROPERTIES MOLDED COATING C-917 _ £ -alßa. SF-502 Physical property: Core density, 28.99 28.36 28.99 kg / m3 (psf) (1.81) (1.77) (1.81) Factor 20 days 0.147 0.143 0.135 Factor K 50 days 0.148 0.146 0.137 Adhesion, kg / cm3 6.3 to 10.7 5, .6 to 10.2 4 .9 to 8. (ASTM D1623) Absorption of water,% in 0.17 0.22 0.18 volume,. { ASTM C-209) The core density, the inner 50 percent of the whole thickness, is representative of the total board performance and the values obtained show that these values are typical. The difference between the K factors of 20 and 50 days is an indication of the ability of the coating to eliminate or minimize the exchange of gases (inlet air and carbon dioxide, HCFC-l41b and HCFC-22 outlet) and shows that these 6.6 polyamide coatings stop the exchange of gases, increasing the R value or the insulation property of these boards. As shown in Table II, adhesion was tested in accordance with ASTM D 1623, and the data obtained on the boards tested indicate that the adhesion between the coatings and polyisocyanurate foam was good to excellent. Finally, the water absorption that is measured using ASTM C 209, is improved over standard glass / paper fiber coating having water absorption values around 1.0 volume percent according to ASTM-C209. In this way, it will be apparent that the device and methods of the present invention are highly effective in providing composite insulation boards useful for roofing and roofing replacement operations as well as insulating boards for walls. The invention is particularly suitable for replacing roofing, but is not necessarily limited thereto. The method of the present invention for manufacturing can be practiced with other equipment, and the method for replenishing roofs can be practiced with the variety of insulation boards that fall within the scope of the present invention. Based on the above description, it should now be apparent that the use of insulation boards described herein will carry out the previously established objectives. Therefore, it should be understood that any apparent variation falls within the scope of the claimed invention and thus, the selection of specific component elements can be determined without departing from the spirit of the invention described and illustrated herein. In particular, boards according to the present invention are not necessarily limited to those having an isocyanurate or polyurethane foam core. Even more as noted previously, the composition of the polymer coating can be varied, particularly with the use of optional fillings and reinforcements. In this way, the scope of the invention will include all modifications and variations that fall within the scope of the appended claims.

Claims

CLAIMS i.- An iso-composite recovery board, characterized in that it comprises: a foam core selected from the group consisting of polyisocyanurate and polyurethane materials and their mixtures; and first and second coatings, between which the foam core is walled, the coatings comprise a polymer sheet selected from the group consisting of polyamides and polycarbonates. 2. - An iso-composite board according to claim 1, characterized in that the coatings further comprise a reinforcing material selected from the group consisting of glass strands, glass fibers, and mixtures thereof. 3. - A composite board according to claim 1, wherein the polyamides are selected from the group consisting of polyamide 6,6, polyamide 6, polyamide 11, polyamide 12 and polyamide 6,10. . - A composite board according to claim 1, characterized in that the polymer 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 their mixtures. 5. - An iso-composite board according to claim 1, characterized in that the foam core comprises polyisocyanurates having an index of 200. 6. - An iso-composite board according to claim 1, characterized in that the foam core comprises polyurethane which it has an index over 120. 7. An iso-composite board according to claim 1, characterized in that the coating has a thickness in the range from about .00127 to about .127 cm (.0005 to .05 in). 8. A composite isolate board according to claim 2, characterized in that the coating comprises the reinforcing material in an amount of about 100 to about 10,000 parts by weight, based on 100 parts by weight of the selected polymer to form the coating. 9. An iso board composed of an entity with claim 1, characterized in that the polycarbonate is poly (4,4-isopropylidene diphenylene carbonate). 10. A composite iso board, according to claim 1, characterized in that the coatings also contain colorants. 11. A method for replacing a roof characterized in that it comprises: applying iso recovery boards to a roof platform, the recovery boards comprising a foam core selected from the group consisting of polyisocyanurate, polyurethane and mixtures thereof; and first and second coatings, between which the foam core is walled, the coatings comprise a polymer sheet selected from the group consisting of polyamides and polycarbonates; and apply a protective layer to the weather on the recovery boards. A method for replenishing a roof according to claim 11, characterized in that the coatings further contain a reinforcing material selected from the group consisting of glass strands, glass fibers and mixtures thereof. A method for replenishing a roof according to claim 11, characterized in that the coatings are essentially devoid of any organic felt materials. A method for replenishing a roof according to claim 11, characterized in that the coating further comprises a filler selected from the group consisting of clay, mica, talc, limestone, gypsum, aluminum trihydrate, antimony oxide, fibers of cellulose, plastic polymer fibers and their mixtures. A method for replenishing a roof according to claim 11, characterized in that the backfill comprises from about 0 to about 5,000 parts by weight per 100 parts by weight of the polymer sheet. 16. A method for replacing a roof in accordance with claim 11, characterized in that the foam core has an index of approximately 250. 17. A method for replenishing a roof according to claim 11, characterized in that the first and second coatings have a thickness in the range between about .00127 to about .127. cm (.0005 to .05 inch). 18. A method for replenishing a roof according to claim 11, characterized in that the step of applying the iso recovery boards to a roof platform comprises placing the iso boards in adjacent parallel stepped sections bordering each other. A method for replenishing a roof according to claim 11, characterized in that the weather protective layer is selected from the group consisting of modified asphalt and EPDM roofing membranes. A method for replenishing a roof according to claim 11, characterized in that it also comprises the step of applying another layer on the weather protective layer selected from the group consisting of engraving, glass stones and their mixtures. 21. A continuous method for producing an iso-composite board, characterized in that it comprises the steps of: feeding a first layer of coating material in a laminator; depositing a foamable liquid polymer on the first layer; feeding a second layer of coating material in the laminator onto the foamable liquid polymer; allowing the liquid polymer to grow during foaming between the first and second coating materials to form polymer foam of a pre-determined thickness; cure the polymer foam under heat to create the iso board; cut the iso board in desired stretches; and stack the boards in bundles. 22. A method according to claim 21, characterized in that the coating material comprises a sheet selected from the group consisting of polyamides and polycarbonates, reinforced with a material selected from the group consisting of glass strands, glass fibers and mixtures thereof. .