Abstract: A coverboard panel may include a first facer layer including a non-porous synthetic polymer, a core layer, and a second facer layer, wherein the core layer is disposed between the first facer layer and the second facer layer, and wherein the coverboard panel is configured to be installed with the first facer layer bonded to a membrane.

Abstract: A method may include 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 form a panel, wherein the hot press causes the bottom facer to shrink 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.

Abstract: A panel including a first layer including fragments from a first blend of paper fragments of a first size and plastic fragments of a second size, a second layer including fragments from a second blend of paper fragments of a third size and plastic fragments of a fourth size, the third size being different from the first size, and the fourth size being different from the second size, and a third layer comprising fragments from the first blend. The second layer is disposed between the first layer and the third layer.

Abstract: Disclosed herein is a roof cover board and a method of manufacturing an improved cover board product. The method includes receiving waste materials or first use materials, the waste materials or first use materials containing a mixture of cellulose, plastic and other materials; separating the cellulose and the plastic from the mixture; shredding the separated cellulose using a first shredder into a stream of cellulose and shredding the separated plastic using a second shredder into a stream of plastic; selecting a cellulose to plastic ratio from a plurality of cellulose to plastic ratios; metering shredded cellulose from the stream of cellulose and shredded plastic from the stream of plastic according to the selected cellulose to plastic ratio; mixing the metered shredded cellulose and plastic; forming said mixture into a mat; and consolidating the mat into a finished good using heat and pressure.

Abstract: A method may include forming a mat including paper fragments, plastic fragments, and top and bottom outer surface layers, wherein the outer surface layers have maximum processing temperature values and consolidating the formed mat in a continuous hot press including three pairs of opposing top and bottom heating platens. A first pair of heating platens has a first heating power. A second pair of heating platens has a second, lower heating power. A third pair of heating platens has a third, even lower heating power. The method may include consolidating the formed mat in a continuous cold press including three pairs of opposing top and bottom heating platens. A first pair of cooling platens has a first cooling power. A second pair of cooling platens has a second, lower cooling power. A third pair of cooling platens and has a third, even lower cooling power.

Abstract: In accordance with some aspects of the present disclosure, a method producing a composite board comprising plastic and cellulose is described. The method includes transmitting a first signal to a pair of opposing hot-platens, receipt of the first signal causing the pair of opposing hot-platens to compress and heat a composite mat; transmitting a second signal to the pair of opposing hot-platens, receipt of the second signal causing the pair of opposing hot-platens to heat and compress the composite mat at substantially a first pressure for a first time period; transmitting a third signal to the pair of opposing hot-platens, receipt of the third signal causing the pair of opposing hot-platens to release the composite mat from the first pressure; and transmitting a fourth signal to a pair of opposing cold-platens, receipt of the fourth signal causing the pair of opposing cold-platens to compress and cool the composite mat.

Abstract: A panel and a method for manufacturing thereof where the panel includes a first layer comprising a first blend of paper fragments and plastic fragments; a second layer comprising a second blend of paper fragments and plastic fragments, wherein the paper fragments and plastic fragments of the second blend are coated with an adhesive; and a third layer comprising the first blend of paper fragments and plastic fragments, wherein the second layer is disposed between the first layer and the third layer, and wherein the first layer, the second layer, and the third layer are combined to form the panel using heat and pressure. In another embodiment, the paper fragments and plastic fragments of the first blend, not the second blend, are coated with an adhesive.

Abstract: Disclosed herein is an improved cover board product with a panel comprising a top surface layer comprised of paper or a fiberglass web; a bottom surface layer comprised of paper, a fiberglass web, nylon film, polyester film, polypropene film, or textiles; and a core layer comprised of paper and thermoplastic fragments connected by a thermoplastic bonding resin. The thermoplastic bonding resin is in a random pattern to less than 100% of the paper and thermoplastic fragment surface area.

Abstract: In accordance with some aspects of the present disclosure, a method producing a composite board comprising plastic and cellulose is described. The method includes transmitting a first signal to a pair of opposing hot-platens, receipt of the first signal causing the pair of opposing hot-platens to compress and heat a composite mat; transmitting a second signal to the pair of opposing hot-platens, receipt of the second signal causing the pair of opposing hot-platens to heat and compress the composite mat at substantially a first pressure for a first time period; transmitting a third signal to the pair of opposing hot-platens, receipt of the third signal causing the pair of opposing hot-platens to release the composite mat from the first pressure; and transmitting a fourth signal to a pair of opposing cold-platens, receipt of the fourth signal causing the pair of opposing cold-platens to compress and cool the composite mat.

Abstract: Disclosed herein is a method of manufacturing an improved cover board product with a panel. In some embodiments, the method includes preparing fragments into an assembly; mixing the fragments and an adhesive into a blended core furnish; applying the adhesive to a top side of a bottom layer fabric in the assembly; forming a core mat of the blended core furnish on top of the adhesive; applying the adhesive to a top side of the core mat; applying a surface layer fabric on the top side of the adhesive; pressing the assembly; and cutting and trimming the assembly to form panels.

Abstract: A panel and a method for manufacturing thereof where the panel includes a first layer comprising a first blend of paper fragments and plastic fragments; a second layer comprising a second blend of paper fragments and plastic fragments, wherein the paper fragments and plastic fragments of the second blend are coated with an adhesive; and a third layer comprising the first blend of paper fragments and plastic fragments, wherein the second layer is disposed between the first layer and the third layer, and wherein the first layer, the second layer, and the third layer are combined to form the panel using heat and pressure. In another embodiment, the paper fragments and plastic fragments of the first blend, not the second blend, are coated with an adhesive.

Abstract: Disclosed herein is a roof cover board and a method of manufacturing an improved cover board product. The method includes receiving waste materials or first use materials, the waste materials or first use materials containing a mixture of cellulose, plastic and other materials; separating the cellulose and the plastic from the mixture; shredding the separated cellulose using a first shredder into a stream of cellulose and shredding the separated plastic using a second shredder into a stream of plastic; selecting a cellulose to plastic ratio from a plurality of cellulose to plastic ratios; metering shredded cellulose from the stream of cellulose and shredded plastic from the stream of plastic according to the selected cellulose to plastic ratio; mixing the metered shredded cellulose and plastic; forming said mixture into a mat; and consolidating the mat into a finished good using heat and pressure.

Abstract: In accordance with some aspects of the present disclosure, a method producing a composite board comprising plastic and cellulose is described. The method includes transmitting a first signal to a pair of opposing hot-platens, receipt of the first signal causing the pair of opposing hot-platens to compress and heat a composite mat; transmitting a second signal to the pair of opposing hot-platens, receipt of the second signal causing the pair of opposing hot-platens to heat and compress the composite mat at substantially a first pressure for a first time period; transmitting a third signal to the pair of opposing hot-platens, receipt of the third signal causing the pair of opposing hot-platens to release the composite mat from the first pressure; and transmitting a fourth signal to a pair of opposing cold-platens, receipt of the fourth signal causing the pair of opposing cold-platens to compress and cool the composite mat.

Abstract: Disclosed herein is a method of manufacturing an improved cover board product with a panel. In some embodiments, the method includes preparing fragments into an assembly; mixing the fragments and an adhesive into a blended core furnish; applying the adhesive to a top side of a bottom layer fabric in the assembly; forming a core mat of the blended core furnish on top of the adhesive; applying the adhesive to a top side of the core mat; applying a surface layer fabric on the top side of the adhesive; pressing the assembly; and cutting and trimming the assembly to form panels.

Abstract: An improved cover board product with a panel comprised of three discrete layers: a top surface layer comprised of either paper or a fiberglass web, a bottom surface layer comprised of either paper or a fiberglass web, and a core layer comprised of discrete paper fragments and polypropylene fragments, which are connected by use of a thermoplastic bonding resin, including polyethylene. The bonding resin is generally attached in a random pattern to less than 100% of the paper fragment and polypropylene fragment surface area. The paper fragments are generally shaped as irregular plates. The polypropylene fragments can have multiple shape types. The two different fragment types are randomly distributed in the core layer relative to each other. The core layer includes small voids in and around the particles, which improves flexibility. The core layer is attached to the top and bottom surface layers by use of a thermoplastic adhesive, including polyethylene.

Abstract: An improved cover board product with a panel comprised of three discrete layers: a top surface layer comprised of either paper or a fiberglass web, a bottom surface layer comprised of either paper or a fiberglass web, and a core layer comprised of discrete paper fragments and polypropylene fragments, which are connected by use of a thermoplastic bonding resin, including polyethylene. The bonding resin is generally attached in a random pattern to less than 100% of the paper fragment and polypropylene fragment surface area. The paper fragments are generally shaped as irregular plates. The polypropylene fragments can have multiple shape types. The two different fragment types are randomly distributed in the core layer relative to each other. The core layer includes small voids in and around the particles, which improves flexibility. The core layer is attached to the top and bottom surface layers by use of a thermoplastic adhesive, including polyethylene.

Abstract: A method of processing municipal solid waste includes extracting food waste, inert materials, and ferrous and non-ferrous metals from the municipal solid waste, shredding the municipal solid waste and thereby generating a product feed comprising at least 99.7% by volume cellulose-based materials and plastic. The product feed is conveyed to a forming system and a manufacturing product is created out of the product feed with the forming system.

Abstract: Described herein are cementitious articles having an integrally formed exterior surface with ultra-smooth finish and reduced porosity and/or thickness relative to the core of the cementitious article. Described herein are also techniques and methods for producing fiber cement articles having a thin exterior shell characterized by improved smoothness and reduced porosity.

Abstract: Described herein are cementitious articles having an integrally formed exterior surface with ultra-smooth finish and reduced porosity and/or thickness relative to the core of the cementitious article. Described herein are also techniques and methods for producing fiber cement articles having a thin exterior shell characterized by improved smoothness and reduced porosity.