Facer and faced polymeric roofing board

Abstract

A prefabricated, faced roofing board composite includes a first board layer made of a polymeric material or a predominantly polymeric material and a fire and weather resistant fiberglass-based facer bonded to a top major surface of the first board layer and forming a top major surface of the composite. The fiberglass-based facer is substantially impervious to the passage of hot gases of combustion, water, and water vapor through the thickness of the fiberglass-based facer. The faced composite can be a cover board, an insulation board; can include cover board and insulation board layers; and can include cover board, insulation board, and baseboard layers. A second fiberglass-based facer that is substantially impervious to the passage of hot gases of combustion through its thickness can form a bottom major surface of the composite. The polymeric material or predominantly polymeric material of the board layer to which each fiberglass-based facer is bonded penetrates part of the way through, but not completely through, the fiberglass-based facer.

1 . A facer for improving the fire resistance and weathering properties of a polymeric material roofing board, comprising:
 a fire and weather resistant fiberglass-based facer having a length, a width, and a thickness; the fiberglass-based facer having first and second major surfaces that are each defined by the length and the width of the fiberglass-based facer; the fiberglass-based facer having a Gurley Porosity of at least  300  and being substantially impervious to the passage of hot gases of combustion and water vapor through the thickness of the fiberglass-based facer; and the fiberglass-based facer having a structure for permitting a limited penetration of a liquid polymeric mixture through the first major surface of the fiberglass-based facer into, but only part of the way through, the fiberglass-based facer when the fiberglass-based facer overlies the liquid polymeric mixture during the formation of a polymeric roofing board from the liquid polymeric mixture to effect a strong bond between the fiberglass-based facer and the polymeric roofing board thus formed without permitting the liquid polymeric mixture to pass through the fiberglass-based facer to the second major surface.   
     
     
         2 . The facer for improving the fire resistance and weathering properties of a polymeric material roofing board according to  claim 1 , wherein:
 the fiberglass-based facer comprises an uncoated fiberglass mat that, in of itself, is substantially impervious to the passage of hot gases of combustion and water vapor.   
     
     
         3 . The facer for improving the fire resistance and weathering properties of a polymeric material roofing board according to  claim 1 , wherein:
 the fiberglass-based facer comprises an uncoated fiberglass mat with mineral filler that combine to make the fiberglass-based facer substantially impervious to the passage of hot gases of combustion and water vapor.   
     
     
         4 . The facer for improving the fire resistance and weathering properties of a polymeric material roofing board according to  claim 1 , wherein:
 the fiberglass-based facer comprises an uncoated fiberglass mat with a polymeric binder that combine to make the fiberglass-based facer substantially impervious to the passage of hot gases of combustion and water vapor.   
     
     
         5 . The facer for improving the fire resistance and weathering properties of a polymeric material roofing board according to  claim 1 , wherein:
 the fiberglass-based facer comprises an uncoated fiberglass mat with mineral filler and a mineral filler carrier that combine to make the fiberglass-based facer substantially impervious to the passage of hot gases of combustion and water vapor.   
     
     
         6 . The facer for improving the fire resistance and weathering properties of a polymeric material roofing board according to  claim 1 , wherein:
 the fiberglass-based facer comprises a fiberglass mat coated on the second major surface with a coating that contains mineral filler and a mineral filler carrier which combine to make the fiberglass-based facer substantially impervious to the passage of hot gases of combustion and water vapor.   
     
     
         7 . A prefabricated, faced roofing board composite, comprising:
 a first board layer made of a polymeric material or a predominantly polymeric material; and a first fire and weather resistant fiberglass-based facer;   the first board layer having a density, a length, a width, and a thickness; the first board layer having a top major surface and a bottom major surface that are each defined by the length and the width of the first board layer;   the first fiberglass-based facer having a length, a width, and a thickness; the first fiberglass-based facer having first and second major surfaces that are each defined by the length and the width of the first fiberglass-based facer; the first fiberglass-based facer having a Gurley porosity of at least  300  and being substantially impervious to the passage of hot gases of combustion and water vapor through the thickness of the first fiberglass-based facer; and   the first fiberglass-based facer being substantially coextensive with and bonded to the top major surface of the first board layer; and the polymeric material or predominantly polymeric material of the first board layer penetrating part of the way through, but not completely through, the first fiberglass-based facer from the first major surface of the first fiberglass-based facer to effect a strong bond between the first fiberglass-based facer and the first board layer while the second major surface of the first fiberglass-based facer is free of the polymeric material or predominantly polymeric material of the first board layer.   
     
     
         8 . The prefabricated, faced roofing board composite according to  claim 7 , wherein:
 the first fiberglass-based facer comprises an uncoated fiberglass mat that, in of itself, is substantially impervious to the passage of hot gases of combustion and water vapor.   
     
     
         9 . The prefabricated, faced roofing board composite according to  claim 7 , wherein:
 the first fiberglass-based facer comprises an uncoated fiberglass mat with mineral filler that combine with the fiberglass mat to make the first fiberglass-based facer substantially impervious to the passage of hot gases of combustion and water vapor.   
     
     
         10 . The prefabricated, faced roofing board composite according to  claim 7 , wherein:
 the first fiberglass-based facer comprises an uncoated fiberglass mat with a polymeric binder that combine with the fiberglass mat to make the first fiberglass-based facer substantially impervious to the passage of hot gases of combustion and water vapor.   
     
     
         11 . The prefabricated, faced roofing board composite according to  claim 7 , wherein:
 the first fiberglass-based facer comprises an uncoated fiberglass mat with a mineral filler and a mineral filler carrier that combine with the fiberglass mat to make the first fiberglass-based facer substantially impervious to the passage of hot gases of combustion and water vapor.   
     
     
         12 . The prefabricated, faced roofing board composite according to  claim 7 , wherein:
 the first fiberglass-based facer comprises a fiberglass mat coated on the second major surface with a coating that contains mineral filler and a mineral filler carrier which combine with the fiberglass mat to make the first fiberglass-based facer substantially impervious to the passage of hot gases of combustion and water vapor.   
     
     
         13 . The prefabricated, faced roofing board composite according to  claim 7 , wherein:
 the polymeric material or predominately polymeric material of the first board layer has an average density between about 1.2 lbs/ft 3  and about 25 lbs/ft 3 .   
     
     
         14 . The prefabricated, faced roofing board composite according to  claim 7 , wherein:
 the polymeric material or predominately polymeric material of the first board layer has an average density between 6 lbs/ft 3  and 25 lbs/ft 3 ; and the prefabricated, faced roofing board composite is a prefabricated, faced cover board composite.   
     
     
         15 . The prefabricated, faced roofing board composite according to  claim 7 , wherein:
 the polymeric material or predominately polymeric material of the first board layer is a high-density polyisocyanurate or predominately polyisocyanurate material.   
     
     
         16 . The prefabricated, faced roofing board composite according to  claim 7 , wherein:
 the polymeric material or predominately polymeric material of the first board layer has an average density of less than 6 lbs/ft 3 ; and the prefabricated, faced roofing board composite is a prefabricated, faced insulation board composite.   
     
     
         17 . The prefabricated, faced roofing board composite according to  claim 7 , wherein:
 the polymeric material or predominately polymeric material of the first board layer is a low-density polyisocyanurate or predominately polyisocyanurate foam material.   
     
     
         18 . The prefabricated, faced roofing board composite according to  claim 7 , including:
 a second fire and weather resistant fiberglass-based facer having a length, a width, and a thickness; the second fiberglass-based facer having first and second major surfaces that are each defined by the length and the width of the second fiberglass-based facer; the second fiberglass-based facer being substantially impervious to the passage of hot gases of combustion through the thickness of the second fiberglass-based facer; and   the second fiberglass-based facer being substantially coextensive with and bonded to the bottom major surface of the first board layer; and the polymeric material or predominantly polymeric material of the first board layer penetrating part of the way through, but not completely through, the second fiberglass-based facer from the first major surface of the second fiberglass-based facer to effect a strong bond between the second fiberglass-based facer and the first board layer while the second major surface of the second fiberglass-based facer is free of the polymeric material or predominantly polymeric material of the first board layer.   
     
     
         19 . The prefabricated, faced roofing board composite according to  claim 7 , including:
 a second board layer made of a polymeric material or a predominantly polymeric material; the second board layer having a length, a width, and a thickness; the second board layer having a top major surface and a bottom major surface that are each defined by the length and the width of the second board layer; the second board layer having a density that differs from the density of the first board layer; and the top major surface of the second board layer being substantially coextensive with and bonded to the bottom major surface of the first board layer.   
     
     
         20 . The prefabricated, faced roofing board composite according to  claim 19 , wherein:
 the polymeric material or predominately polymeric material of the first board layer has an average density between 6 lbs/ft 3  and 25 lbs/ft 3 ; and the first board layer forms a cover board layer of the prefabricated, faced roofing board composite; and   the polymeric material or predominately polymeric foam material of the second board layer has an average density less than 6 lbs/ft 3 ; and the second board layer forms an insulation board layer of the prefabricated, faced roofing board composite.   
     
     
         21 . The prefabricated, faced roofing board composite according to  claim 19 , wherein:
 the polymeric material or predominately polymeric material of the first board layer is a high-density polyisocyanurate or predominately polyisocyanurate material; and   the polymeric material or predominately polymeric foam material of the second board layer is a low-density polyisocyanurate or predominately polyisocyanurate foam material.   
     
     
         22 . The prefabricated, faced roofing board composite according to  claim 19 , including:
 a second fire and weather resistant fiberglass-based facer having a length, a width, and a thickness; the second fiberglass-based facer having first and second major surfaces that are each defined by the length and the width of the second fiberglass-based facer; the second fiberglass-based facer being substantially impervious to the passage of hot gases of combustion through the thickness of the second fiberglass-based facer; and   the second fiberglass-based facer being substantially coextensive with and bonded to the bottom major surface of the second board layer; and the polymeric material or predominantly polymeric foam material of the second board layer penetrating part of the way through, but not completely through, the second fiberglass-based facer from the first major surface of the second fiberglass-based facer to effect a strong bond between the second fiberglass-based facer and the second board layer while the second major surface of the second fiberglass-based facer is free of the polymeric material or predominantly polymeric foam material of the second board layer.   
     
     
         23 . The prefabricated, faced roofing board composite according to  claim 7 , including:
 a second board layer made of a polymeric material or a predominantly polymeric foam material; the second board layer having a length, a width, and a thickness; the second board layer having a top major surface and a bottom major surface that are each defined by the length and the width of the second board layer; the second board layer having a density that differs from and is less than the density of the first board layer; and the top major surface of the second board layer being substantially coextensive with and bonded to the bottom major surface of the first board layer; and   a third board layer made of a polymeric material or a predominantly polymeric material; the third board layer having a length, a width, and a thickness; the third board layer having a top major surface and a bottom major surface that are each defined by the length and the width of the third board layer; the third board layer having a density that differs from and is greater than the density of the second board layer; and the top major surface of the third board layer being substantially coextensive with and bonded to the bottom major surface of the second board layer.   
     
     
         24 . The prefabricated, faced roofing board composite according to  claim 23 , wherein:
 the polymeric material or predominately polymeric material of the first board layer has an average density between 6 lbs/ft 3  and 25 lbs/ft 3 ; and the first board layer forms a cover board layer of the prefabricated, faced roofing board composite;   the polymeric material or predominately polymeric foam material of the second board layer has an average density less than 6 lbs/ft 3 ; and the second board layer forms an insulation board layer of the prefabricated, faced roofing board composite; and   the polymeric material or predominately polymeric material of the third board layer has an average density between 6 lbs/ft 3  and 25 lbs/ft 3 ; and the third board layer forms a baseboard layer of the prefabricated, faced roofing board composite.   
     
     
         25 . The prefabricated, faced roofing board composite according to  claim 23 , wherein:
 the polymeric material or predominately polymeric material of the first and third board layers is a high-density polyisocyanurate or predominately polyisocyanurate material; and   the polymeric material or predominately polymeric foam material of the second board layer is a low-density polyisocyanurate or predominately polyisocyanurate foam material.   
     
     
         26 . The prefabricated, faced roofing board composite according to  claim 23 , including:
 a second fire resistant fiberglass-based facer having a length, a width, and a thickness; the second fiberglass-based facer having first and second major surfaces that are each defined by the length and the width of the second fiberglass-based facer; the second fiberglass-based facer being substantially impervious to the passage of hot gases of combustion through the thickness of the second fiberglass-based facer; and   the second fiberglass-based facer being substantially coextensive with and bonded to the bottom major surface of the third board layer; and the polymeric material or predominantly polymeric material of the third board layer penetrating part of the way through, but not completely through, the second fiberglass-based facer from the first major surface of the second fiberglass-based facer to effect a strong bond between the second fiberglass-based facer and the third board layer while the second major surface of the second fiberglass-based facer is free of the polymeric material or predominantly polymeric material of the third board layer.   
     
     
         27 . A facer for improving the fire resistance and weathering properties of a polymeric material roofing board, comprising:
 a fire and weather resistant fiberglass-based facer having a length, a width, and a thickness; the fiberglass-based facer having first and second major surfaces that are each defined by the length and the width of the fiberglass-based facer; the fiberglass-based facer comprising between about 15% and 25% by weight fiberglass mat and between about 75% and 85% by weight a polymeric based coating material containing an inorganic filler; the fiberglass based facer being substantially impervious to the passage of hot gases of combustion and water vapor through the thickness of the fiberglass-based facer; and the fiberglass-based facer having a structure for permitting a limited penetration of a liquid polymeric mixture through the first major surface of the fiberglass-based facer into, but only part of the way through, the fiberglass-based facer when the fiberglass-based facer overlies the liquid polymeric mixture during the formation of a polymeric roofing board from the liquid polymeric mixture to effect a strong bond between the fiberglass-based facer and the polymeric roofing board thus formed without permitting the liquid polymeric mixture to pass through the fiberglass-based facer to the second major surface.   
     
     
         28 . The facer for improving the fire resistance and weathering properties of a polymeric material roofing board, according to  claim 27 , wherein:
 the polymeric based coating material of the fiberglass-based facer is a latex based coating material; and the fiberglass-based facer has a Gurley porosity of at least 300.   
     
     
         29 . A prefabricated, faced roofing board composite, comprising:
 a first board layer made of a polymeric material or a predominantly polymeric material; and a first fire and weather resistant fiberglass-based facer;   the first board layer having a density, a length, a width, and a thickness; the first board layer having a top major surface and a bottom major surface that are each defined by the length and the width of the first board layer;   the first fiberglass-based facer having a length, a width, and a thickness; the first fiberglass-based facer having first and second major surfaces that are each defined by the length and the width of the first fiberglass-based facer; the first fiberglass-based facer comprising between about 15% and 25% by weight fiberglass mat and between about 75% and 85% by weight a polymeric based coating material containing an inorganic filler; the first fiberglass-based facer being substantially impervious to the passage of hot gases of combustion and water vapor through the thickness of the first fiberglass-based facer; and   the first fiberglass-based facer being substantially coextensive with and bonded to the top major surface of the first board layer; and the polymeric material or predominantly polymeric material of the first board layer penetrating part of the way through, but not completely through, the first fiberglass-based facer from the first major surface of the first fiberglass-based facer to effect a strong bond between the first fiberglass-based facer and the first board layer while the second major surface of the first fiberglass-based facer is free of the polymeric material or predominantly polymeric material of the first board layer.   
     
     
         30 . The prefabricated, faced roofing board composite according to  claim 29 , wherein:
 the polymeric based coating material of the first fiberglass-based facer is a latex based coating material; and the first fiberglass-based facer has a Gurley porosity of at least 300.   
     
     
         31 . The prefabricated, faced roofing board composite according to  claim 29 , wherein:
 the polymeric material or predominately polymeric material of the first board layer has an average density between about 1.2 lbs/ft 3  and about 25 lbs/ft 3 .   
     
     
         32 . The prefabricated, faced roofing board composite according to  claim 29 , wherein:
 the polymeric material or predominately polymeric material of the first board layer has an average density between 6 lbs/ft 3  and 25 lbs/ft 3 ; and the prefabricated, faced roofing board composite is a prefabricated, faced cover board composite.   
     
     
         33 . The prefabricated, faced roofing board composite according to  claim 29 , wherein:
 the polymeric material or predominately polymeric material of the first board layer is a high-density polyisocyanurate or predominately polyisocyanurate material.   
     
     
         34 . The prefabricated, faced roofing board composite according to  claim 29 , wherein:
 the polymeric material or predominately polymeric material of the first board layer has an average density of less than 6 lbs/ft 3 ; and the prefabricated, faced roofing board composite is a prefabricated, faced insulation board composite.   
     
     
         35 . The prefabricated, faced roofing board composite according to  claim 29 , wherein:
 the polymeric material or predominately polymeric material of the first board layer is a low-density polyisocyanurate or predominately polyisocyanurate foam material.   
     
     
         36 . The prefabricated, faced roofing board composite according to  claim 29 , including:
 a second fire and weather resistant fiberglass-based facer having a length, a width, and a thickness; the second fiberglass-based facer having first and second major surfaces that are each defined by the length and the width of the second fiberglass-based facer; the second fiberglass-based facer comprising between about 15% and 25% by weight fiberglass mat and between about 75% and 85% by weight a polymeric based coating material containing an inorganic filler; the second fiberglass-based facer being substantially impervious to the passage of hot gases of combustion through the thickness of the second fiberglass-based facer; and   the second fiberglass-based facer being substantially coextensive with and bonded to the bottom major surface of the first board layer; and the polymeric material or predominantly polymeric material of the first board layer penetrating part of the way through, but not completely through, the second fiberglass-based facer from the first major surface of the second fiberglass-based facer to effect a strong bond between the second fiberglass-based facer and the first board layer while the second major surface of the second fiberglass-based facer is free of the polymeric material or predominantly polymeric material of the first board layer.   
     
     
         37 . The prefabricated, faced roofing board composite according to  claim 29 , including:
 a second board layer made of a polymeric material or a predominantly polymeric material; the second board layer having a length, a width, and a thickness; the second board layer having a top major surface and a bottom major surface that are each defined by the length and the width of the second board layer; the second board layer having a density that differs from the density of the first board layer; and the top major surface of the second board layer being substantially coextensive with and bonded to the bottom major surface of the first board layer.   
     
     
         38 . The prefabricated, faced roofing board composite according to  claim 37 , wherein:
 the polymeric material or predominately polymeric material of the first board layer has an average density between 6 lbs/ft 3  and 25 lbs/ft 3 ; and the first board layer forms a cover board layer of the prefabricated, faced roofing board composite; and   the polymeric material or predominately polymeric foam material of the second board layer has an average density less than 6 lbs/ft 3 ; and the second board layer forms an insulation board layer of the prefabricated, faced roofing board composite.   
     
     
         39 . The prefabricated, faced roofing board composite according to  claim 37 , wherein:
 the polymeric material or predominately polymeric material of the first board layer is a high-density polyisocyanurate or predominately polyisocyanurate material; and   the polymeric material or predominately polymeric foam material of the second board layer is a low-density polyisocyanurate or predominately polyisocyanurate foam material.   
     
     
         40 . The prefabricated, faced roofing board composite according to  claim 37 , including:
 a second fire and weather resistant fiberglass-based facer having a length, a width, and a thickness; the second fiberglass-based facer having first and second major surfaces that are each defined by the length and the width of the second fiberglass-based facer; the second fiberglass-based facer comprising between about 15% and 25% by weight fiberglass mat and between about 75% and 85% by weight a polymeric based coating material containing an inorganic filler; the second fiberglass-based facer being substantially impervious to the passage of hot gases of combustion through the thickness of the second fiberglass-based facer; and   the second fiberglass-based facer being substantially coextensive with and bonded to the bottom major surface of the second board layer; and the polymeric material or predominantly polymeric foam material of the second board layer penetrating part of the way through, but not completely through, the second fiberglass-based facer from the first major surface of the second fiberglass-based facer to effect a strong bond between the second fiberglass-based facer and the second board layer while the second major surface of the second fiberglass-based facer is free of the polymeric material or predominantly polymeric foam material of the second board layer.   
     
     
         41 . The prefabricated, faced roofing board composite according to  claim 29 , including:
 a second board layer made of a polymeric material or a predominantly polymeric foam material; the second board layer having a length, a width, and a thickness; the second board layer having a top major surface and a bottom major surface that are each defined by the length and the width of the second board layer; the second board layer having a density that differs from and is less than the density of the first board layer; and the top major surface of the second board layer being substantially coextensive with and bonded to the bottom major surface of the first board layer; and   a third board layer made of a polymeric material or a predominantly polymeric material; the third board layer having a length, a width, and a thickness; the third board layer having a top major surface and a bottom major surface that are each defined by the length and the width of the third board layer; the third board layer having a density that differs from and is greater than the density of the second board layer; and the top major surface of the third board layer being substantially coextensive with and bonded to the bottom major surface of the second board layer.   
     
     
         42 . The prefabricated, faced roofing board composite according to  claim 41 , wherein:
 the polymeric material or predominately polymeric material of the first board layer has an average density between 6 lbs/ft 3  and 25 lbs/ft 3 ; and the first board layer forms a cover board layer of the prefabricated, faced roofing board composite;   the polymeric material or predominately polymeric foam material of the second board layer has an average density less than 6 lbs/ft 3 ; and the second board layer forms an insulation board layer of the prefabricated, faced roofing board composite; and   the polymeric material or predominately polymeric material of the third board layer has an average density between 6 lbs/ft 3  and 25 lbs/ft 3 ; and the third board layer forms a baseboard layer of the prefabricated, faced roofing board composite.   
     
     
         43 . The prefabricated, faced roofing board composite according to  claim 41 , wherein:
 the polymeric material or predominately polymeric material of the first and third board layers is a high-density polyisocyanurate or predominately polyisocyanurate material; and   the polymeric material or predominately polymeric foam material of the second board layer is a low-density polyisocyanurate or predominately polyisocyanurate foam material.   
     
     
         44 . The prefabricated, faced roofing board composite according to  claim 41 , including:
 a second fire resistant fiberglass-based facer having a length, a width, and a thickness; the second fiberglass-based facer having first and second major surfaces that are each defined by the length and the width of the second fiberglass-based facer; the second fiberglass-based facer comprising between about 15% and 25% by weight fiberglass mat and between about 75% and 85% by weight a polymeric based coating material containing an inorganic filler; the second fiberglass-based facer being substantially impervious to the passage of hot gases of combustion through the thickness of the second fiberglass-based facer; and   the second fiberglass-based facer being substantially coextensive with and bonded to the bottom major surface of the third board layer; and the polymeric material or predominantly polymeric material of the third board layer penetrating part of the way through, but not completely through, the second fiberglass-based facer from the first major surface of the second fiberglass-based facer to effect a strong bond between the second fiberglass-based facer and the third board layer while the second major surface of the second fiberglass-based facer is free of the polymeric material or predominantly polymeric material of the third board layer.