초록 ▼

A prefabricated cover board has a high-density polymer or predominantly polymer material core layer having a density between 6 lbs/ft3 and 25 lbs/ft3. A prefabricated roofing panel composite includes the cover board and an insulation board that has a low-density polymer or predominantly polymer mate

A prefabricated cover board has a high-density polymer or predominantly polymer material core layer having a density between 6 lbs/ft3 and 25 lbs/ft3. A prefabricated roofing panel composite includes the cover board and an insulation board that has a low-density polymer or predominantly polymer material foam core layer having a density less than 6 lbs/ft3. The cover board may have a waterproofing membrane forming the top major surface of the cover board. When making the roofing panel composite, the low-density foam core layer of the insulation board may be formed with the high-density core layer of the cover board being currently or subsequently formed over and bonded to a top major surface of the low-density foam core layer in the same operation or preformed insulation boards may be fed into a production line with the high-density core layer of the cover board being formed over and bonded to top major surfaces of the low-density foam core layers of the insulation boards.

대표청구항 ▼

What is claimed is: 1. A prefabricated roofing system panel comprising: a cover board; the cover board comprising a high-density predominantly polymer material core layer, the high-density core layer of the cover board having a density between 6 lbs/ft3 and 25 lbs/ft3 and a thickness of about 0.08

What is claimed is: 1. A prefabricated roofing system panel comprising: a cover board; the cover board comprising a high-density predominantly polymer material core layer, the high-density core layer of the cover board having a density between 6 lbs/ft3 and 25 lbs/ft3 and a thickness of about 0.08 inches or greater; the high-density core layer of the cover board having a length, a width, and a thickness; the high density core layer of the cover board having a top major surface and a bottom major surface that are each defined by the length and the width of the high density core layer, an insulation board, the insulation board comprising a low-density predominantly polymer material foam core layer; the low-density foam core layer of the insulation board having a density less than 6 lbs/ft3 and a thickness of about 0.50 inches or greater; the low-density foam core layer of the insulation board having a length, a width, and a thickness; the low-density foam core layer of the insulation board having a top major surface and a bottom major surface that are each defined by the length and the width of the low-density foam core layer; the bottom major surface of the high-density core layer of the cover board and the top major surface of the low-density foam core layer of the insulation board being substantially coextensive; and the cover board and the insulation board have a common nonwoven mat facer that overlies and is bonded to the bottom major surface of the high-density core layer of the cover board and the top major surface of the low-density foam core layer of the insulation board to bond the cover board and the insulation board together; wherein the cover board includes a top facer overlying and bonded to the top major surface of the high-density predominately polymer material core layer, and the top facer comprises a nonwoven mat. 2. The prefabricated roofing system panel according to claim 1, wherein: the nonwoven mat of the top facer is a nonwoven fiberglass mat. 3. The prefabricated roofing system panel according to claim 2, wherein: the top facer is a waterproof membrane. 4. The prefabricated roofing system panel according to claim 3, wherein: the top facer extends beyond a side edge and an end edge of the top major surface of the high-density predominately polymer material core layer of the cover board. 5. The prefabricated roofing system panel according to claim 1, wherein: the lengths and widths of the high-density core layer of the cover board and the low-density foam core layer of the insulation board are each about 4 feet or greater. 6. The prefabricated roofing system panel according to claim 1, wherein: the thickness of the high-density core layer of the cover board is between about 0.08 inches and about 0.75 inches; the thickness of the low-density foam core layer of the insulation board is between about 0.50 inches and about 6 inches; the lengths of the high-density core layer of the cover board and the low-density foam core layer of the insulation board are each about 8 feet or greater; and the widths of the high-density core layer of the cover board and the low-density foam core layer of the insulation board are each about 4 feet or greater. 7. The prefabricated roofing system panel according to claim 6, wherein: the polymer material of the high-density core layer of the cover board and the low-density foam core layer of the insulation board is polyisocyanurate. 8. The prefabricated roofing system panel according to claim 7, wherein: the high-density core layer of the cover board is a high-density predominantly polymer material foam core layer. 9. The prefabricated roofing system panel according to claim 1, wherein: the nonwoven mat of the common nonwoven mat facer is a fiberglass mat. 10. The prefabricated roofing system panel according to claim 9, wherein: the insulation board includes a bottom facer that overlies and is bonded to the bottom major surface of the low-density foam core layer of the insulation board; and the bottom facer comprises a nonwoven mat. 11. The prefabricated roofing system panel according to claim 1, including: a baseboard comprising a high-density predominantly polymer material core layer; the high-density core layer of the baseboard having a density between 6 lbs/ft3 and 25 lbs/ft3; the high-density core layer of the baseboard having a length, a width, and a thickness; the high-density core layer of the baseboard having a top major surface and a bottom major surface that are defined by the length and the width of the high-density core layer of the baseboard; and the bottom major surface of the low-density foam core layer of the insulation board is bonded to die top major surface of the high-density core layer of the baseboard; and the bottom major surface of the low-density foam core layer of the insulation board and the top major surface of the high-density core layer of the baseboard are substantially coextensive. 12. The prefabricated roofing system panel according to claim 11, wherein: the cover board includes a top facer overlying and bonded to the top major surface of the high-density predominately polymer material core layer, the baseboard includes a bottom facer that overlies and is bonded to the bottom major surface of the high-density core layer of the baseboard; and the baseboard and the insulation board have a common facer that overlies and is bonded to the top major surface of the high-density core layer of the baseboard and the bottom major surface of the low-density foam care layer of the insulation board. 13. The prefabricated roofing system panel according to claim 12, wherein: the top facer, the bottom facer, and the common facers each comprise a nonwoven mat. 14. The prefabricated roofing system panel according to claim 13, wherein: the top facer is a waterproof membrane. 15. A roofing system comprising: a cover board; the cover board comprising a high-density predominantly polymer material core layer, the high-density core layer of the cover board having a density between 6 lbs/ft3 and 25 lbs/ft3 and a thickness of about 0.08 inches or greater; the high-density core layer of the cover board having a length, a width, and a thickness; the high density core layer of the cover board having a top major surface and a bottom major surface that are each defined by the length and the width of the high density core layer, an insulation board, the insulation board comprising a low-density predominantly polymer material foam core layer; the low-density foam core layer of the insulation board having a density less than 6 lbs/ft3 and a thickness of about 0.50 inches or greater; the low-density foam core layer of the insulation board having a length, a width, and a thickness; the low-density foam core layer of the insulation board having a top major surface and a bottom major surface that are each defined by the length and the width of the low-density foam core layer; and wherein the cover board and the insulation board have a nonwoven mat facer between them that overlies and is bonded to at least the top major surface of the low-density foam core layer of the insulation board; and wherein the cover board includes a top facer overlying and bonded to the top major surface of the high-density predominately polymer material core layer, and the top facer comprises a nonwoven mat. 16. The roofing system according to claim 15, wherein: the nonwoven mat of the top facer is a nonwoven fiberglass mat. 17. The roofing system according to claim 16, wherein: the top facer is a waterproof membrane. 18. The roofing system according to claim 17, wherein: the top facer extends beyond a side edge and an end edge of the top major surface of the high-density predominately polymer material core layer of the cover board. 19. The roofing system according to claim 15, wherein: the lengths and widths of the high-density core layer of the cover board and the low-density foam core layer of the insulation board are each about 4 feet or greater. 20. The roofing system according to claim 15, wherein: the thickness of the high-density core layer of the cover board is between about 0.08 inches and about 0.75 inches; the thickness of the low-density foam core layer of the insulation board is between about 0.50 inches and about 6 inches; the lengths of the high-density core layer of the cover board and the low-density foam core layer of the insulation board are each about 8 feet or greater; and the widths of the high-density core Layer of the cover board and the low-density foam core layer of the insulation board are each about 4 feet or greater. 21. The roofing system according to claim 15, wherein: the polymer material of the high-density core layer of the cover board and the low-density foam core layer of the insulation board is polyisocyanurate. 22. The roofing system according to claim 21, wherein: the high-density core layer of the cover board is a high-density predominantly polymer material foam core layer. 23. The roofing system according to claim 15, wherein: the nonwoven mat of the nonwoven mat facer between the cover board and the insulation board is a fiberglass mat. 24. The roofing system according to claim 23, wherein: the insulation board includes a bottom facer that overlies and is bonded to the bottom major surface of the low-density foam core layer of the insulation board; and the bottom facer comprises a nonwoven mat.