Cup-resistant roof coverboard panels
A method may include placing a bottom facer on a conveyor, placing a core layer on the bottom facer placing a top facer on the core layer, and pressing the bottom facer, the core layer, and the top facer in a hot press to form a panel, wherein the hot press causes the bottom facer to shrink relative to the top facer, introducing a warp into the panel such that, when installed, the warp compensates for an installation warp and the panel is flat upon installation.
1. A method comprising:
placing a bottom facer on a conveyor;
placing a core layer on the bottom facer;
placing a top facer on the core layer; and
pressing the bottom facer, the core layer, and the top facer in a hot press to thermally fuse a mixture of paper fragments and plastic fragments in the core layer to form a panel such that the bottom facer shrinks relative to the top facer, introducing a warp into the panel such that, when installed, the warp compensates for an installation warp and the panel is flat upon installation.
2. The method of claim 1 , wherein the installation warp is based on expected fastening sites.
3. The method of claim 2 , wherein the installation warp is greater with the expected fastening sites in a field region of the panel than with the expected fastening sites in a perimeter region of the panel.
4. The method of claim 1 , wherein the warp has a first direction opposite a second direction of the installation warp.
5. The method of claim 1 , wherein the bottom facer has an unconstrained shrinkage level of greater than 1%.
6. The method of claim 1 , wherein the bottom facer layer is a synthetic polymer sheet good.