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.

What is claimed is: 
     
         1 . A method comprising:
 (a) preparing an A-side stream of reactants including an isocyanate and optionally flame-retardants, surfactants, blowing agents and other non-isocyanate-reactive components;   (b) preparing a B-side stream of reactants including a isocyanate reactive compound, a blowing agent, and optionally flame retardants, catalysts, emulsifiers/solubilizers, surfactants, blowing agents, fillers, fungicides, and anti-static substances;   (c) admixing the A-side stream of reactants with the B-side stream of reactants to form a developing foam, where the amount of blowing agent present in said B-side is adjusted to achieve a final foam product having a density of greater than 2.5 pounds per cubic foot;   (d) depositing the developing foam on a first facer;   (e) mating a second facer to the developing foam;   (f) heating the foam within a laminator; and   (g) cutting the foam into a foam board.   
     
     
         2 . The method of  claim 2 , where the isocyanate is a mixtures of diphenyl methane diisocyanates and oligomers thereof. 
     
     
         3 . The method of  claim 3 , where the isocyanate-reactive compound is a polyester polyol or a polyester polyol. 
     
     
         4 . The method of  claim 1 , where the facer of said coverboard is formed of materials selected from the group consisting of coated glass fiber mats, uncoated glass fiber mats, chopped glass, and combinations thereof. 
     
     
         5 . The method of  claim 1 , where the foam board has a thickness that is greater than 0.5 inches. 
     
     
         6 . 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;   (c) a coverboard including a polyurethane, a polyisocyanurate, or a mix of polyurethane and polyisocyanurate cellular structure, said coverboard having a density greater than 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; and   (d) a membrane covering.   
     
     
         7 . The roof of  claim 6 , where the facer of said coverboard is formed of materials selected from the group consisting of coated glass fiber mats, uncoated glass fiber mats, chopped glass, and combinations thereof. 
     
     
         8 . The roof of  claim 7 , where said insulation board is positioned above said roof deck, said coverboard is positioned above said insulation board, and said membrane is positioned above said coverboard. 
     
     
         9 . The roof of  claim 8 , where the coverboard has a thickness that is greater than 0.5 inches. 
     
     
         10 . The roof of  claim 6 , where the membrane is an EPDM membrane. 
     
     
         11 . A roof system comprising:
 (a) a roof deck; and   (b) a polyurethane or polyisocyanurate foam board directly in contact with said roof deck, where the polyurethane or polyisocyanurate has a density that is greater than 2.5 pounds per cubic foot.   
     
     
         12 . The roof system of  claim 11 , where the roof deck is a concrete pads, a steel decks, a wood beam deck, or a foamed concrete deck. 
     
     
         13 . The roof system of  claim 11 , where the foam board includes oppositely positioned facers. 
     
     
         14 . The roof system of  claim 13 , where the facers include fiber boards, gypsum products such as densdeck, and perlite boards. 
     
     
         15 . The roof system of  claim 13 , where the facers included coated glass fiber mats, uncoated glass fiber mats, chopped glass, and combinations thereof.