US 11,808,040 B2
Insulation board with improved performance
Matthew Leatherman, Carlisle, PA (US); Xuan Zhang, Carlisle, PA (US); and Cody Turnow, York, PA (US)
Assigned to CARLISLE CONSTRUCTION MATERIALS, LLC, Carlisle, PA (US)
Filed by CARLISLE CONSTRUCTION MATERIALS, LLC, Carlisle, PA (US)
Filed on Sep. 9, 2020, as Appl. No. 17/015,295.
Application 17/015,295 is a continuation of application No. 16/601,203, filed on Oct. 14, 2019, granted, now 10,801,205.
Claims priority of provisional application 62/819,089, filed on Mar. 15, 2019.
Claims priority of provisional application 62/749,530, filed on Oct. 23, 2018.
Prior Publication US 2020/0399901 A1, Dec. 24, 2020
This patent is subject to a terminal disclaimer.
Int. Cl. B32B 37/12 (2006.01); B32B 37/15 (2006.01); B32B 38/00 (2006.01); E04D 1/28 (2006.01); E04B 1/90 (2006.01); B32B 5/24 (2006.01); B32B 5/02 (2006.01); B32B 5/26 (2006.01); B32B 17/06 (2006.01); B29C 43/46 (2006.01); B29C 43/44 (2006.01); E04B 1/74 (2006.01)
CPC E04D 1/28 (2013.01) [B29C 43/44 (2013.01); B29C 43/46 (2013.01); B32B 5/022 (2013.01); B32B 5/024 (2013.01); B32B 5/245 (2013.01); B32B 5/26 (2013.01); B32B 17/067 (2013.01); B32B 37/12 (2013.01); B32B 37/153 (2013.01); E04B 1/90 (2013.01); B32B 2038/0084 (2013.01); B32B 2250/03 (2013.01); B32B 2250/05 (2013.01); B32B 2250/40 (2013.01); B32B 2255/02 (2013.01); B32B 2255/26 (2013.01); B32B 2262/0253 (2013.01); B32B 2305/022 (2013.01); B32B 2305/188 (2013.01); B32B 2305/20 (2013.01); B32B 2307/7265 (2013.01); B32B 2309/105 (2013.01); B32B 2323/00 (2013.01); B32B 2375/00 (2013.01); B32B 2419/06 (2013.01); E04B 2001/742 (2013.01)] 17 Claims
OG exemplary drawing
 
1. A method of forming an insulation board assembly, comprising:
(a) providing a first roll of facer material, the first roll of facer material being woven and having a tensile strength greater than 80 lbf/3 inch in both a machine direction and a cross direction and a weight of 20 to 200gsm;
(b) providing a second roll of facer material, the second roll of facer material being woven and having a tensile strength greater than 80 lbf/3 inch in both a machine direction and a cross direction and a weight of 20 to 200gsm;
(c) applying foam between the first and second rolls of facer material to form an insulation board assembly that when adhered or mechanically fastened onto a roof assembly permits the roof assembly to meet the Very Severe Hail rating of FM 4470 (Class 1); and
(d) adhering or mechanically fastening the insulation board assembly onto a roof assembly such that the roof assembly meets the Very Severe Hail rating of FM 4470 (Class 1).