Prefabricated roofing panel composite

Abstract

A prefabricated roofing panel composite includes a prefabricated cover board having a high-density polymer or predominantly polymer material core layer having a density between 6 lbs/ft 3 and 25 lbs/ft 3 and an insulation board that has a low-density polymer or predominantly polymer material foam core layer having a density less than or equal to about 2 lbs/ft 3 . The cover board may have a waterproofing membrane forming the top major surface of the cover board. 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.

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/ft 3  and 25 lbs/ft 3 ; 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 or equal to about 2 lbs/ft 3 ; 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   the bottom major surface of the high-density core layer of the cover board being bonded to the top major surface of the low-density foam core layer of the insulation board; and 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.   
   
   
       2 . The prefabricated roofing system panel according to  claim 1 , wherein:
 the thickness of the high-density core layer of the cover board is about 0.25-0.5 inches; and the thickness of the low density foam core layer of the insulation board is about 0.50-3.50 inches.   
   
   
       3 . 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.   
   
   
       4 . The prefabricated roofing system panel according to  claim 1 , wherein:
 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.   
   
   
       5 . The prefabricated roofing system panel according to  claim 1 , 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.   
   
   
       6 . The prefabricated roofing system panel according to  claim 1 , wherein:
 the high-density core layer of the cover board is a high-density predominantly polymer material foam core layer.   
   
   
       7 . The prefabricated roofing system panel according to  claim 1 , wherein:
 the cover board includes a top facer that overlies and is bonded to the top major surface of the high-density core layer of the cover board;   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 cover board and the insulation board have a common 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.   
   
   
       8 . The prefabricated roofing system panel according to  claim 7 , wherein:
 the top facer of the cover board is a waterproofing membrane.   
   
   
       9 . 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/ft 3  and 25 lbs/ft 3 ; 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 being 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 core layer of the insulation board and the top major surface of the high-density core layer of the baseboard being substantially coextensive.   
   
   
       10 . The prefabricated roofing system panel according to  claim 9 , wherein:
 the cover board includes a top facer that overlies and is bonded to the top major surface of the high-density core layer of the cover board;   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;   the cover board and the insulation board have a common 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; 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 core layer of the insulation board.   
   
   
       11 . The prefabricated roofing system panel according to  claim 10 , wherein:
 the top facer of the cover board is a waterproofing membrane.   
   
   
       12 . A method of making prefabricated roofing system panels, comprising:
 forming an insulation board comprising a low-density predominantly polymer material foam core layer having a density of less than or equal to about 2 lbs/ft 3  in a continuous process wherein the low-density foam core layer of the insulation board formed has a width, a thickness, a continuous length, and 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 of the insulation board;   forming a cover board comprising a high-density predominantly polymer material core layer having a density between 6 lbs/ft 3  and 25 lbs/ft 3  in a continuous process wherein the high-density core layer of the cover board formed has a width, a thickness, a continuous length, and 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 of the cover board; and   forming the widths of the low-density foam core layer of the insulation board and the high-density core layer of the cover board to be substantially the same with the core layer of one of the boards being formed over and bonded to one of the major surfaces of the core layer of the other board to form a composite.   
   
   
       13 . The method of making prefabricated roofing system panels according to  claim 12 , wherein:
 the core layers of the insulation board and the cover board are formed concurrently.   
   
   
       14 . The method of making prefabricated roofing system panels according to  claim 12 , wherein:
 the thickness of the high-density core layer of the cover board is about 0.25-0.5 inches; and the thickness of the low density foam core layer of the insulation board is about 0.50-3.50 inches.   
   
   
       15 . The method of making prefabricated roofing system panels according to  claim 12 , wherein:
 the widths of the high-density foam core layer of the cover board and the low-density foam core layer of the insulation board are each about 4 feet or greater; and the composite formed by the high-density foam core layer of the cover board and the low-density foam core layer of the insulation board is periodically cut to form roofing systems panels that are each about 4 feet or greater in length.   
   
   
       16 . The method of making prefabricated roofing system panels according to  claim 12 , wherein:
 the widths of the high-density foam core layer of the cover board and the low-density foam core layer of the insulation board are each about 4 feet or greater; and the composite formed by the high-density core layer of the cover board and the low-density foam core layer of the insulation board is periodically cut to form roofing system panels that are each about 8 feet or greater in length.   
   
   
       17 . The method of making prefabricated roofing system panels according to  claim 12 , 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.   
   
   
       18 . The method of making prefabricated roofing system panels according to  claim 12 , wherein:
 the high-density core layer of the cover board is formed over and bonded to the top major surface of the low-density foam core layer of the insulation board.   
   
   
       19 . The method of making prefabricated roofing system panels according to  claim 12 , including:
 applying a top facer to the low-density foam core layer of the insulation board during the formation of the low-density foam core layer of the insulation board that overlies and is bonded to the top major surface of the low-density foam core layer of the insulation board and applying a bottom facer to the low-density foam core layer of the insulation board during the formation of the low-density foam core layer of the insulation board that overlies and is bonded to the bottom major surface of the low-density foam core layer of the insulation board;   applying a top facer to the high-density core layer of the cover board during the formation of the high-density core layer of the cover board that overlies and is bonded to the top major surface of the high-density core layer of the cover board; and   forming the high-density core layer of the cover board on the top facer of the low-density foam core layer of the insulation board whereby the top facer of the low-density foam core layer of the insulation board becomes a common facer for the high-density foam core layer of the cover board and the low-density foam core layer of the insulation board.   
   
   
       20 . The method of making prefabricated roofing system panels according to  claim 19 , wherein: the top facer applied to the top major surface of the high-density core layer of the cover board is a waterproofing membrane. 
   
   
       21 . A method of making prefabricated roofing system panels, comprising:
 feeding a series of insulation boards that each comprise a low-density predominantly polymer material foam core layer having a density of less than or equal to about 2 lbs/ft 3  into a production line in a continuous process; the low-density foam core layer of each of the insulation boards having a width, a thickness, a length, and 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 of the insulation board;   forming a cover board comprising a high-density predominantly polymer material core layer having a density between 6 lbs/ft 3  and 25 lbs/ft 3  and a width substantially equal to the widths of the low-density foam core layers of the insulation boards; the high-density core layer of the cover board being formed in a continuous process over and bonded to the top major surfaces of the low-density foam core layers of the insulation boards fed into the production line to form a composite; and   the composite being cut to the lengths of the low-density foam core layers of the insulation boards fed into the production line.   
   
   
       22 . The method of making prefabricated roofing system panels according to  claim 21 , wherein:
 the thickness of the high-density core layer of the cover board is about 0.25-0.5 inches; and the thickness of low-density foam core layer of each of the insulation boards is about 0.50-3.50 inches;   
   
   
       23 . The method of making prefabricated roofing system panels according to  claim 21 , wherein:
 the widths of the high-density core layer of the cover board and the low-density foam core layers of each of the insulation boards are each about 4 feet or greater; and the composite formed by the high-density core layer of the cover board and the low-density foam core layers of each of the insulation boards is periodically cut to form roofing systems panels that are each about 4 feet or greater in length.   
   
   
       24 . The method of making prefabricated roofing system panels according to  claim 21 , wherein:
 the widths of the high-density core layer of the cover board and the low-density foam core layers of each of the insulation boards are each about 4 feet or greater; and the composite formed by the high-density core layer of the cover board and the low-density foam core layers of each of the insulation boards is periodically cut to form roofing system panels that are each about 8 feet or greater in length.   
   
   
       25 . The method of making prefabricated roofing system panels according to  claim 21 , wherein:
 the polymer material of the high-density core layer of the cover board and the low-density foam core layers of each of the insulation boards is polyisocyanurate.   
   
   
       26 . The method of making prefabricated roofing system panels according to  claim 21 , wherein:
 the low-density foam core layers of each of the insulation boards have top and bottom facers that overlie and are bonded to the top and bottom major surfaces of the low-density foam core layers of each of the insulation boards; and   a top facer is applied to the high-density core layer of the cover board during the formation of the high-density core layer of the cover board that overlies and is bonded to a top major surface of the high-density core layer of the cover board and the top facers of the low-density foam core layers of the insulation boards become a bottom facer for the high-density core layer of the cover board.   
   
   
       27 . The method of making prefabricated roofing system panels according to  claim 26 , wherein:
 the top facer applied to the top major surface of the high-density core layer of the cover board is a waterproofing membrane.   
   
   
       28 . 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/ft 3  and 25 lbs/ft 3 ; 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 or equal to about 2 lbs/ft 3 ; 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.   
   
   
       29 . The prefabricated roofing system panel according to  claim 28 , 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.   
   
   
       30 . The prefabricated roofing system panel according to  claim 29 , wherein:
 the nonwoven mat of the top facer is a nonwoven fiberglass mat.   
   
   
       31 . The prefabricated roofing system panel according to  claim 30 , wherein:
 the top facer is a waterproof membrane.   
   
   
       32 . The prefabricated roofing system panel according to  claim 31 , 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.   
   
   
       33 . The prefabricated roofing system panel according to  claim 28 , wherein:
 the thickness of the high-density core layer of the cover board is about 0.25-0.5 inches; and the thickness of the low density foam core layer of the insulation board is about 0.50-3.50 inches.   
   
   
       34 . The prefabricated roofing system panel according to  claim 28 , 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.   
   
   
       35 . The prefabricated roofing system panel according to  claim 28 , wherein:
 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.   
   
   
       36 . The prefabricated roofing system panel according to  claim 35 , 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.   
   
   
       37 . The prefabricated roofing system panel according to  claim 36 , wherein:
 the high-density core layer of the cover board is a high-density predominantly polymer material foam core layer.   
   
   
       38 . The prefabricated roofing system panel according to  claim 28 , wherein:
 the nonwoven mat of the common nonwoven mat facer is a fiberglass mat.   
   
   
       39 . The prefabricated roofing system panel according to  claim 38 , 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.   
   
   
       40 . The prefabricated roofing system panel according to  claim 28 , 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/ft 3  and 25 lbs/ft 3 ; 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 the 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.   
   
   
       41 . The prefabricated roofing system panel according to  claim 40 , 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 core layer of the insulation board.   
   
   
       42 . The prefabricated roofing system panel according to  claim 41 , wherein:
 the top facer, the bottom facer, and the common facers each comprise a nonwoven mat.   
   
   
       43 . The prefabricated roofing system panel according to  claim 42 , wherein:
 the top facer is a waterproof membrane.