Roofing systems and methods

Patent metadata

Field	Value
Publication number	US-9404261-B2
Application number	US-201414293004-A
Country	US
Kind code	B2
Filing date	Jun 2, 2014
Priority date	Nov 9, 2004
Publication date	Aug 2, 2016
Grant date	Aug 2, 2016

Abstract

According to one aspect, a roofing system includes a plurality of insulation boards adapted for overlying a roof deck to form a layer of insulation. Each of the plurality of insulation boards includes a first polyisocyanurate foam having a first foam density. The roofing system further includes a plurality of cover boards adapted for overlying the layer of insulation. Each of the plurality of cover boards includes a second polyisocyanurate foam having a second foam density, and the second foam density is greater than the first foam density. Each of the insulation boards and cover boards may have a facer on at least one major surface. The second foam density may be selected to provide the cover boards with a compressive strength to resist deformation.

First claim

What is claimed is:

1. A method of constructing a roof, the method comprising:
receiving a plurality of insulation boards and a plurality of cover boards, each of the plurality of insulation boards comprising a first polyisocyanurate foam having a first polyisocyanurate foam density and each of the plurality of cover boards comprising a second polyisocyanurate foam having a second polyisocyanurate foam density, wherein the second polyisocyanurate foam density is greater than the first polyisocyanurate foam density; and
installing at least some of the insulation boards and at least some of the cover boards on a roof deck with the installed insulation boards overlying the roof deck and the installed cover boards overlying the installed insulation boards.

2. A roofing system, comprising:
a plurality of insulation boards overlying a roof deck to form a layer of insulation, each of the plurality of insulation boards comprising a first polyisocyanurate or predominantly polyisocyanurate foam material having a first foam density; and
a plurality of cover boards overlying the layer of insulation, each of the plurality of cover boards comprising a second polyisocyanurate or predominantly polyisocyanurate foam material having a second foam density;
wherein the second foam density is greater than the first foam density, which greater foam density provides for a compressive strength to resist deformation.

3. The roofing system of claim 2 , wherein:
each of the plurality of insulation boards has opposing top and bottom major surfaces and comprises a facer on at least one of the major surfaces of the insulation board; and
each of the plurality of cover boards has opposing top and bottom major surfaces and comprises a facer on at least one of the major surfaces of the cover board.

4. The roofing system of claim 2 , wherein the second foam density is between 6 lbs/ft 3 and 25 lbs/ft 3 .

5. The roofing system of claim 2 , wherein the second foam density is between 4 lbs/ft 3 and 25 lbs/ft 3 .

6. The roofing system of claim 2 , wherein each of the plurality of cover boards is bonded to a respective one of the plurality of insulation boards to form a roofing panel composite.

7. The roofing system of claim 2 , further comprising a waterproofing membrane overlying the layer of cover boards.

8. A roofing system, comprising:
a plurality of insulation boards overlying a roof deck to form a layer of insulation, each of the plurality of insulation boards comprising a first polyisocyanurate foam having a first polyisocyanurate foam density; and
a plurality of cover boards overlying the layer of insulation, each of the plurality of cover boards comprising a second polyisocyanurate foam having a second polyisocyanurate foam density;
wherein the second polyisocyanurate foam density is greater than the first polyisocyanurate foam density.

9. The roofing system of claim 8 , wherein:
each of the plurality of insulation boards has opposing top and bottom major surfaces and comprises a facer on at least one of the major surfaces of the insulation board; and
each of the plurality of cover boards has opposing top and bottom major surfaces and comprises a facer on at least one of the major surfaces of the cover board.

10. The roofing system of claim 8 , wherein the second polyisocyanurate foam density is selected to provide the cover boards with a compressive strength to resist deformation.

11. The roofing system of claim 8 , wherein the second polyisocyanurate foam density is between 6 lbs/ft 3 and 25 lbs/ft 3 .

12. The roofing system of claim 8 , wherein the second polyisocyanurate foam density is between 4 lbs/ft 3 and 25 lbs/ft 3 .

13. The roofing system of claim 8 , wherein each of the plurality of cover boards has a thickness, and wherein the thickness and the second polyisocyanurate foam density are selected to provide the cover boards with a compressive strength to resist deformation and protect low-density insulation layers overlaid by the cover board from damage.

14. The roofing system of claim 13 , wherein:
each of the plurality of insulation boards has opposing top and bottom major surfaces and comprises a facer on at least one of the major surfaces of the insulation board; and
each of the plurality of cover boards has opposing top and bottom major surfaces and comprises a facer on at least one of the major surfaces of the cover board.

15. The roofing system of claim 14 , wherein the second polyisocyanurate foam density is between 6 lbs/ft 3 and 25 lbs/ft 3 .

16. The roofing system of claim 14 , wherein the second polyisocyanurate foam density is between 4 lbs/ft 3 and 25 lbs/ft 3 .

17. The roofing system of claim 8 , wherein each of the plurality of cover boards is bonded to a respective one of the plurality of insulation boards to form a roofing panel composite.

18. The roofing system of claim 8 , further comprising a waterproofing membrane overlying the layer of cover boards.

Assignees

• Johns Manville

Inventors

• Johnson Walter Alexander
• Hazy Joel Evan
• Paradis Duane
• Griffin Christopher J
• Swann Raymond C
• Burdic Brad C

Classifications

• B32B5/18

  characterised by features of a layer {of} foamed material · CPC title

• B32B2419/06

  Roofs, roof membranes · CPC title

• E04B7/22

  the slabs having insulating properties, e.g. laminated with layers of insulating material · CPC title

• B32B2307/72

  Density · CPC title

• B32B5/022

  Non-woven fabric · CPC title