Roofing system and method for preparing the same

Abstract

A roof system comprising a roof deck, an insulation layer, a coverboard disposed over said insulation layer, where said coverboard includes a foam core and a facer including a fibrous mat and an interfacial region disposed between said core and said mat, and a layer of asphalt.

What is claimed is: 
     
         1 . A roof system comprising:
 (i) a roof deck;   (ii) an insulation layer;   (iii) a coverboard disposed over said insulation layer, where said coverboard includes a foam core and a facer including a fibrous mat and an interfacial region disposed between said core and said mat; and   (iv) a layer of asphalt.   
     
     
         2 . The roof system of  claim 1 , where said insulation layer includes foamed polyurethane, polyisocyanurate, polystyrene, or a mixture of two or more thereof. 
     
     
         3 . The roof system of  claim 1 , where said foam core includes polyisocyanurate foam. 
     
     
         4 . The roof system of  claim 1 , where said foam core of said coverboard includes polyisocyanurate foam having a density, as defined by ASTM C303, of greater than 2.5 pounds per cubic foot. 
     
     
         5 . The roof system of  claim 1 , where said foam core of said coverboard includes polyisocyanurate foam having a density, as defined by ASTM C303, of greater than 3.5 pounds per cubic foot. 
     
     
         6 . The roof system of  claim 1 , where said foam core of said coverboard includes polyisocyanurate foam having a density, as defined by ASTM C303, of less than 5.5 pounds per cubic foot. 
     
     
         7 . The roof system of  claim 1 , where the layer of asphalt is applied to said coverboard as a hot melt. 
     
     
         8 . The roof system of  claim 1 , where said interfacial region is a polymeric interfacial region. 
     
     
         9 . The roof system of  claim 1 , where said mat is a glass mat. 
     
     
         10 . The roof system of  claim 1 , where the build-up roof system includes at least one layer of sealant material. 
     
     
         11 . A method for installing a roof system, the method comprising:
 (i) applying a layer of coverboards to a layer of insulation, where the coverboards include a foam core and a facer including a fibrous mat and an interfacial region disposed between said core and said mat; and   (ii) applying a liquefied hot-melt sealant directly to the coverboard.   
     
     
         12 . The roof system of  claim 11 , where said insulation layer includes foamed polyurethane, polyisocyanurate, polystyrene, or a mixture of two or more thereof. 
     
     
         13 . The roof system of  claim 11 , where said foam core includes polyisocyanurate foam. 
     
     
         14 . The roof system of  claim 11 , where said foam core of said coverboard includes polyisocyanurate foam having a density, as defined by ASTM C303, of greater than 2.5 pounds per cubic foot. 
     
     
         15 . The roof system of  claim 11 , where said foam core of said coverboard includes polyisocyanurate foam having a density, as defined by ASTM C303, of greater than 3.5 pounds per cubic foot. 
     
     
         16 . The roof system of  claim 11 , where said foam core of said coverboard includes polyisocyanurate foam having a density, as defined by ASTM C303, of less than 5.5 pounds per cubic foot. 
     
     
         17 . The roof system of  claim 11 , where said step of applying a liquefied hot-melt sealant includes applying hot asphalt. 
     
     
         18 . The roof system of  claim 11 , where said interfacial region is a polymeric interfacial region. 
     
     
         19 . The roof system of  claim 11 , where said mat is a glass mat. 
     
     
         20 . The roof system of  claim 11 , where the roof system includes at least one layer of sealant material.