High density polyurethane and polyisocyanurate construction boards and composite boards

Abstract

A covered roof includes a roof deck, an insulation board, and a coverboard. The insulation board includes a polyurethane, a polyisocyanurate, or a mix of polyurethane and polyisocyanurate cellular structure, has a density that is less than 2.5 pounds per cubic foot, and has a first planar surface and a second planar surface, each having a facer positioned adjacent thereto. The coverboard includes a polyurethane, a polyisocyanurate, or a mix of polyurethane and polyisocyanurate cellular structure, has a density greater than about 2.5 pounds per cubic foot and less than 6 pounds per cubic foot, an iso index of at least 175, and a first planar surface and a second planar surface, each having a facer positioned adjacent thereto.

1 . A covered roof comprising:
 a roof deck;   an insulation board including a polyurethane, a polyisocyanurate, or a mix of polyurethane and polyisocyanurate cellular structure, said insulation board having a density that is less than 2.5 pounds per cubic foot, and said insulation board having a first planar surface and a second planar surface, said first planar surface and said second planar surface each having a facer positioned adjacent thereto; and   a coverboard including a polyurethane, a polyisocyanurate, or a mix of polyurethane and polyisocyanurate cellular structure, said coverboard having a density greater than about 2.5 pounds per cubic foot and less than 6 pounds per cubic foot, an iso index of at least 175, and a first planar surface and a second planar surface, said first planar surface and said second planar surface each having a facer positioned adjacent thereto.   
     
     
         2 . A covered roof according to  claim 1 , wherein said density of said coverboard is greater than about 3 pounds per cubic foot. 
     
     
         3 . A covered roof according to  claim 2 , wherein said density of said coverboard is between about 4 and 5 pounds per cubic foot. 
     
     
         4 . A covered roof according to  claim 1 , wherein said density of said insulation board is less than 2.2 pounds per cubic foot. 
     
     
         5 . A covered roof according to  claim 1 , wherein said facers on said coverboard are formed from a material selected from a group of materials including coated glass fiber mats, uncoated glass fiber mats, and chopped glass. 
     
     
         6 . A covered roof according to  claim 1 , wherein at least one of said facers on said insulation board and said facers on said coverboard is formed from materials selected from the group consisting of aluminum foil, cellulosic fibers, reinforced cellulosic fibers, craft paper, coated glass fiber mats, uncoated glass fiber mats, chopped glass, fiber board, perlite board, and gypsum board. 
     
     
         7 . A covered roof according to  claim 1 , wherein said coverboard thickness is from about 0.5 to about 4.5 inches. 
     
     
         8 . A covered roof according to  claim 1  further comprising a protective membrane. 
     
     
         9 . A covered roof according to  claim 8 , wherein said protective membrane includes a polymeric membrane. 
     
     
         10 . A covered roof according to  claim 8 , wherein said protective membrane includes a bituminous or asphalt membrane. 
     
     
         11 . A covered roof according to  claim 8 , wherein said protective membrane derives from the application of hot asphalt to the roof. 
     
     
         12 . A method comprising:
 (a) applying a coverboard to a roof, wherein the coverboard includes a polyurethane, a polyisocyanurate, or a mix of polyurethane and polyisocyanurate cellular structure, said re-coverboard having a density that is greater than about 2.5 pounds per cubic foot and less than 6 pounds per cubic foot, an iso index of at least 175, and a first planar surface and a second planar surface, said first planar surface and said second planar surface having a facer positioned adjacent thereto; and   (b) applying an insulation board to said roof, said insulation board including a polyurethane, a polyisocyanurate, or a mix of polyurethane and polyisocyanurate cellular structure, said re-insulation board having a density that is less than 2.5 pounds per cubic foot.   
     
     
         13 . A method according to  claim 12 , wherein said density of said coverboard is between about 4 and 5 pounds per cubic foot. 
     
     
         14 . A method according to  claim 12 , wherein said density of said insulation board is less than 2.2 pounds per cubic foot. 
     
     
         15 . A method according to  claim 12  further comprising the step of applying a protective membrane to said roof after said steps of applying a coverboard and applying an insulation board. 
     
     
         16 . A method according to  claim 15 , wherein said protective membrane includes a polymeric membrane. 
     
     
         17 . A method according to  claim 15 , wherein said protective membrane includes a bituminous or asphalt membrane. 
     
     
         18 . A method according to  claim 15 , wherein said protective membrane derives from the application of hot asphalt to the roof.