Composite roofing members having improved dimensional...

E - Fixed Constructions – 04 – D

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E04D 13/16 (2006.01) B32B 5/18 (2006.01) E04C 2/24 (2006.01) E04C 2/296 (2006.01) E04D 3/35 (2006.01) E04D 12/00 (2006.01)

Patent

CA 2216027

A composite recovery board (10) comprises a foam core (11) selected from the group consisting of polyisocyanurate and polyurethane materials and mixtures thereof; a facer (15), applied to one major surface (13) of the foam core and comprising a sheet selected from the group consisting of reinforced polymer material and reinforced cellulosic material, wherein the polymer material and cellulosic material are reinforced with a material selected from the group consisting of glass strands, glass fibers, and mixtures thereof and, gypsum board (14), applied to the opposite major surface (12) of the foam core. A method of reroofing a roof comprises applying composite recovery boards of the present invention to a roof deck; and, applying a weather protective layer over the recovery boards. A continuous method of making a composite recovery board comprises feeding gypsum board (14) into a laminator assembly (21); depositing a foamable polymer liquid (36) onto the gypsum board; feeding a facer material (15) into the laminator assembly above the foamable polymer liquid; allowing the polymer liquid to rise between the gypsum board and facer material forming polymer foam of a pre-determined thickness; curing the polymer foam under heat (44) to create the composite board; and cutting the composite board to desired lengths.

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