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) a roof deck;   (b) 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   (c) 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 high density construction board comprising:
 a cellular body having a first planar surface and a second planar surface, a first facer adjacent said first planar surface and a second facer adjacent said second planar surface, wherein said cellular body includes a polyurethane, a polyisocyanurate, or a mix of polyurethane and polyisocyanurate and has a density greater than about 2.5 pounds per cubic foot and less than 6 pounds per cubic foot, and wherein said first facer and said second facer are formed from materials selected from the group consisting of coated glass fiber mats, uncoated glass fiber mats, chopped glass, and combinations thereof.   
     
     
         3 . 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.   
     
     
         4 . A covered roof comprising:
 (a) a roof deck; and   (b) a high density construction board comprising a cellular body having a first planar surface and a second planar surface, a first facer adjacent said first planar surface and a second facer adjacent said second planar surface, wherein said cellular body includes a polyurethane, a polyisocyanurate, or a mix of polyurethane and polyisocyanurate and has a density greater than about 2.5 pounds per cubic foot and less than 6 pounds per cubic foot, and wherein said first facer and said second facer are formed from materials selected from the group consisting of coated glass fiber mats, uncoated glass fiber mats, chopped glass, and combinations thereof.   
     
     
         5 . A method of covering a roof comprising:
 applying a high density construction board to the roof, the high density construction board comprising a cellular body having a first planar surface and a second planar surface, a first facer adjacent said first planar surface and a second facer adjacent said second planar surface, wherein said cellular body includes a polyurethane, a polyisocyanurate, or a mix of polyurethane and polyisocyanurate and has a density greater than about 2.5 pounds per cubic foot and less than 6 pounds per cubic foot, and wherein said first facer and said second facer are formed from materials selected from the group consisting of coated glass fiber mats, uncoated glass fiber mats, chopped glass, and combinations thereof.