Composite roofing members having improved dimensional stability and related methods

Abstract

A composite recovery board (10) includes 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 formed from 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 includes 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 includes 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.

Dependencies are inferred from the claim text.