Construction boards with coated inorganic facer

Abstract

A method for preparing a construction board, the method comprising (i) providing a non-woven mat having a coating layer disposed on a planar surface thereof, where the coating layer includes an inorganic filler dispersed within a polymeric matrix; (ii) contacting an A-side stream of reactants including an isocyanate compound with a B-side stream of reactants including an isocyanate-reactive compound to prepare a developing foam; and (iii) depositing the developing foam on to said coating of said non-woven mat.

What is claimed is: 
     
         1 . A method for preparing a construction board, the method comprising:
 (i) providing a non-woven mat having a coating layer disposed on a planar surface thereof, where the coating layer includes an inorganic filler dispersed within a polymeric matrix;   (ii) contacting an A-side stream of reactants including an isocyanate compound with a B-side stream of reactants including an isocyanate-reactive compound to prepare a developing foam; and   (iii) depositing the developing foam on to said coating of said non-woven mat.   
     
     
         2 . The method of  claim 1 , further comprising the step of heating the developing foam within a laminator. 
     
     
         3 . The method of  claim 2 , wherein after said step of depositing the developing foam on to said coating and prior to heating the developing foam, mating said developing foam to a facer. 
     
     
         4 . The method of  claim 3 , wherein said facer includes a coating layer disposed on a planar surface thereof, where the coating includes an inorganic filler dispersed within a polymeric matrix. 
     
     
         5 . The method of  claim 1 , where said inorganic filler is selected from the group consisting of limestone, calcium carbonate, clay, talc, mica, perlite, hollow ceramic spheres, and combinations thereof. 
     
     
         6 . The method of  claim 1 , where said coating includes at least 80% by weight filler and from about 1 to about 15% by weight matrix. 
     
     
         7 . The method of  claim 1 , where said matrix is a polymeric binder. 
     
     
         8 . The method of  claim 4 , where said step of mating said developing foam to a facer includes mating the developing foam to the coating layer disposed on a planar surface thereof. 
     
     
         9 . The method of  claim 8 , where said facer includes a coating layer disposed on each of two opposed planar surfaces of said facer. 
     
     
         10 . The method of  claim 9 , where said facer includes a non-woven mat having said coating layers. 
     
     
         11 . A roof system comprising:
 (i) a roof deck;   (ii) a construction board; and   (iii) a membrane, where the construction board includes:
 (a) a foam core having first and second planar surfaces, where the foam core includes a polyisocyanurate cellular structure having an index of at least 175 and being formed by contacting an A-side stream of reactants including an isocyanate compound and a B-side stream of reactants including an isocyanate-reactive compound; 
 (b) an interfacial region including a filler dispersed within a matrix, said interfacial region being disposed on said first planar surface of said foam core; and 
 (c) a non-woven inorganic mat disposed on said interfacial region opposite said foam such that said core and said mat sandwich said interfacial region. 
   
     
     
         12 . The roof system of  claim 11 , where said construction board further comprises a coating layer disposed on said non-woven inorganic mat opposite said interfacial region. 
     
     
         13 . The roof system of  claim 12 , where said coating layer includes filler dispersed within a matrix. 
     
     
         14 . The roof system of  claim 13 , where said filler includes an inorganic filler. 
     
     
         15 . The roof system of  claim 14 , where said inorganic filler is selected from the group consisting of limestone, calcium carbonate, clay, talc, mica, perlite, hollow ceramic spheres, and combinations thereof. 
     
     
         16 . The roof system of  claim 15 , where said coating includes at least 80% by weight filler and from about 1 to about 15% by weight matrix. 
     
     
         17 . The roof system of  claim 16 , where said matrix is a polymeric binder. 
     
     
         18 . The roof system of  claim 11 , where said filler within said interfacial region is an inorganic filler. 
     
     
         19 . The roof system of  claim 18 , where said inorganic filler is selected from the group consisting of limestone, calcium carbonate, clay, talc, mica, perlite, hollow ceramic spheres, and combinations thereof. 
     
     
         20 . The roof system of  claim 19 , where said matrix of said interfacial region is a polymeric binder.