Composite roofing members having improved dimensional stability and related methods

Abstract

A composite recovery board (10) containing a foam core (11) of polyisocyanurate, polyurethane materials or mixtures thereof; a facer (15), applied to one major surface (13) of the foam core, where the facer includes polymer materials, reinforced polymer materials, cellulosic materials, paper, aluminum foil or trilaminates thereof, wherein the reinforced polymer material and the cellulosic material are reinforced with glass strands, glass fibers, or mixtures thereof; and, gypsum board (14), applied to the opposite major surface (12) of the foam core. A method of reroofing a roof by 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 by 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.