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.

What is claimed is: 
     
         1 - 20 . (canceled) 
     
     
         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 02.5-0.5 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 - 43 . (canceled)