US 12,247,398 B2
Cup-resistant roof coverboard panels
Jack G. Winterowd, Puyallup, WA (US); Matthew Spencer, Palatine, IL (US); and Marko Suput, Lompoc, CA (US)
Assigned to CONTINUUS MATERIALS INTELLECTUAL PROPERTY, LLC, The Woodlands, TX (US)
Filed by Continuus Materials Intellectual Property, LLC, The Woodlands, TX (US)
Filed on Mar. 31, 2023, as Appl. No. 18/129,225.
Claims priority of provisional application 63/408,913, filed on Sep. 22, 2022.
Prior Publication US 2024/0102288 A1, Mar. 28, 2024
Int. Cl. B32B 37/14 (2006.01); B27N 3/06 (2006.01); B29C 65/48 (2006.01); B29C 65/66 (2006.01); E04D 3/34 (2006.01); B29C 65/00 (2006.01); B29L 31/10 (2006.01); B32B 7/028 (2019.01); B32B 7/12 (2006.01); B32B 37/12 (2006.01)
CPC E04D 3/34 (2013.01) [B29C 65/4815 (2013.01); B29C 65/66 (2013.01); B32B 37/144 (2013.01); B27N 3/06 (2013.01); B29C 66/73715 (2013.01); B29L 2031/108 (2013.01); B32B 7/028 (2019.01); B32B 7/12 (2013.01); B32B 2037/1223 (2013.01); B32B 2250/03 (2013.01); B32B 2307/736 (2013.01); B32B 2419/06 (2013.01)] 6 Claims
OG exemplary drawing
 
1. A method comprising:
placing a bottom facer on a conveyor;
placing a core layer on the bottom facer;
placing a top facer on the core layer; and
pressing the bottom facer, the core layer, and the top facer in a hot press to thermally fuse a mixture of paper fragments and plastic fragments in the core layer to form a panel such that the bottom facer shrinks relative to the top facer, introducing a warp into the panel such that, when installed, the warp compensates for an installation warp and the panel is flat upon installation.