Prefabricated roofing panel composite
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, wherein the high-density predominantly polymer material of the cover board core layer comprises polyisocyanurate;
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 as 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 corer 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 rooting 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 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 as 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.
13. The prefabricated roofing system panel according to claim 12 , 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.
14. The prefabricated roofing system panel according to claim 13 , wherein:
the nonwoven mat of the top facer is a nonwoven fiberglass mat.
15. The prefabricated roofing system panel according to claim 14 , wherein:
the top facer is a waterproof membrane.
16. The prefabricated rooting system panel according to claim 15 , wherein:
the top lacer 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.
17. The prefabricated roofing system panel according to claim 12 , wherein:
the thickness of the high-density core layer of the cover hoard 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.
18. The prefabricated roofing system panel according to claim 12 , 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.
19. The prefabricated roofing system panel according to claim 12 , wherein:
the lengths of the high-density core layer of the cover hoard 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.
20. The prefabricated roofing system panel according to claim 19 , wherein:
the polymer material of the high-density core layer of the cover board anti the low-density foam core layer of the insulation board is polyisocyanurate.
21. The prefabricated rooting system panel according claim 20 , wherein:
high-density core layer of the cover board is a high-density predominantly polymer material foam core layer.
22. The prefabricated roofing system panel according to claim 12 , wherein:
the nonwoven mat of the common nonwoven mat facer is a fiberglass mat.
23. The prefabricated roofing system panel according to claim 22 , 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.
24. The prefabricated roofing system panel according to claim 12 , including:
a baseboard comprising as thigh-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 as 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.
25. The prefabricated roofing system panel according to claim 24 , 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.
26. The prefabricated roofing system panel according to claim 25 , wherein:
the top facer, the bottom facer, and the common facers each comprise a nonwoven mat.
27. The prefabricated rooting system panel according to claim 26 , wherein:
the top facer is a waterproof membrane.