CA2340451C - Foamed facer and insulation boards made therefrom - Google Patents
Foamed facer and insulation boards made therefrom Download PDFInfo
- Publication number
- CA2340451C CA2340451C CA002340451A CA2340451A CA2340451C CA 2340451 C CA2340451 C CA 2340451C CA 002340451 A CA002340451 A CA 002340451A CA 2340451 A CA2340451 A CA 2340451A CA 2340451 C CA2340451 C CA 2340451C
- Authority
- CA
- Canada
- Prior art keywords
- facer
- mat
- insulation board
- fiber
- core
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 238000009413 insulation Methods 0.000 title claims abstract description 49
- 239000000203 mixture Substances 0.000 claims abstract description 43
- 239000006260 foam Substances 0.000 claims abstract description 36
- 239000000835 fiber Substances 0.000 claims abstract description 35
- 229920000126 latex Polymers 0.000 claims abstract description 25
- 239000004816 latex Substances 0.000 claims abstract description 23
- 238000004519 manufacturing process Methods 0.000 claims abstract description 12
- 229920000642 polymer Polymers 0.000 claims abstract description 12
- 239000011521 glass Substances 0.000 claims abstract description 10
- 238000000034 method Methods 0.000 claims abstract description 9
- 239000004094 surface-active agent Substances 0.000 claims abstract description 8
- 230000008569 process Effects 0.000 claims abstract description 6
- 230000009974 thixotropic effect Effects 0.000 claims abstract description 6
- 239000011347 resin Substances 0.000 claims abstract description 5
- 229920005989 resin Polymers 0.000 claims abstract description 5
- 230000000979 retarding effect Effects 0.000 claims abstract description 3
- 238000005728 strengthening Methods 0.000 claims abstract description 3
- 238000000576 coating method Methods 0.000 claims description 31
- 239000011248 coating agent Substances 0.000 claims description 30
- 239000003365 glass fiber Substances 0.000 claims description 12
- -1 C22 fatty acid Chemical class 0.000 claims description 8
- 239000004604 Blowing Agent Substances 0.000 claims description 6
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 6
- 238000005187 foaming Methods 0.000 claims description 6
- 238000003475 lamination Methods 0.000 claims description 6
- JPNZKPRONVOMLL-UHFFFAOYSA-N azane;octadecanoic acid Chemical compound [NH4+].CCCCCCCCCCCCCCCCCC([O-])=O JPNZKPRONVOMLL-UHFFFAOYSA-N 0.000 claims description 5
- 239000003063 flame retardant Substances 0.000 claims description 5
- 239000011256 inorganic filler Substances 0.000 claims description 5
- 229910003475 inorganic filler Inorganic materials 0.000 claims description 5
- 239000002562 thickening agent Substances 0.000 claims description 5
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 claims description 4
- 229940088990 ammonium stearate Drugs 0.000 claims description 4
- 239000003795 chemical substances by application Substances 0.000 claims description 4
- 239000000758 substrate Substances 0.000 claims description 4
- RREGISFBPQOLTM-UHFFFAOYSA-N alumane;trihydrate Chemical group O.O.O.[AlH3] RREGISFBPQOLTM-UHFFFAOYSA-N 0.000 claims description 3
- 238000001035 drying Methods 0.000 claims description 3
- 239000000546 pharmaceutical excipient Substances 0.000 claims description 3
- 150000003863 ammonium salts Chemical class 0.000 claims description 2
- 238000009435 building construction Methods 0.000 claims description 2
- 239000003086 colorant Substances 0.000 claims description 2
- 235000014113 dietary fatty acids Nutrition 0.000 claims description 2
- 239000000194 fatty acid Substances 0.000 claims description 2
- 229930195729 fatty acid Natural products 0.000 claims description 2
- 239000003017 thermal stabilizer Substances 0.000 claims description 2
- 239000013036 UV Light Stabilizer Substances 0.000 claims 2
- 239000011230 binding agent Substances 0.000 abstract description 10
- 229920001187 thermosetting polymer Polymers 0.000 abstract description 4
- 238000010276 construction Methods 0.000 abstract description 2
- 239000012764 mineral filler Substances 0.000 abstract description 2
- 238000002360 preparation method Methods 0.000 abstract 1
- 239000011162 core material Substances 0.000 description 41
- 239000000126 substance Substances 0.000 description 15
- 238000001723 curing Methods 0.000 description 14
- 239000011888 foil Substances 0.000 description 9
- 229920000582 polyisocyanurate Polymers 0.000 description 9
- 239000011495 polyisocyanurate Substances 0.000 description 9
- 239000010426 asphalt Substances 0.000 description 7
- 230000032798 delamination Effects 0.000 description 7
- 229920002635 polyurethane Polymers 0.000 description 7
- 239000004814 polyurethane Substances 0.000 description 7
- 239000004800 polyvinyl chloride Substances 0.000 description 7
- 229920000915 polyvinyl chloride Polymers 0.000 description 7
- 239000008199 coating composition Substances 0.000 description 6
- 239000011152 fibreglass Substances 0.000 description 6
- 239000010410 layer Substances 0.000 description 6
- 239000007788 liquid Substances 0.000 description 6
- 239000012528 membrane Substances 0.000 description 6
- 239000004698 Polyethylene Substances 0.000 description 5
- 229920000573 polyethylene Polymers 0.000 description 5
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 4
- 239000000654 additive Substances 0.000 description 4
- 239000000853 adhesive Substances 0.000 description 4
- 230000001070 adhesive effect Effects 0.000 description 4
- 238000006243 chemical reaction Methods 0.000 description 4
- 239000000945 filler Substances 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 239000004793 Polystyrene Substances 0.000 description 3
- 229910052782 aluminium Inorganic materials 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 3
- 239000000839 emulsion Substances 0.000 description 3
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 3
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 description 3
- 229920001568 phenolic resin Polymers 0.000 description 3
- 229920002223 polystyrene Polymers 0.000 description 3
- 239000005995 Aluminium silicate Substances 0.000 description 2
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 description 2
- RGSFGYAAUTVSQA-UHFFFAOYSA-N Cyclopentane Chemical compound C1CCCC1 RGSFGYAAUTVSQA-UHFFFAOYSA-N 0.000 description 2
- 229920003270 Cymel® Polymers 0.000 description 2
- 229920000877 Melamine resin Polymers 0.000 description 2
- OFBQJSOFQDEBGM-UHFFFAOYSA-N Pentane Chemical compound CCCCC OFBQJSOFQDEBGM-UHFFFAOYSA-N 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 2
- 229920002125 Sokalan® Polymers 0.000 description 2
- 229920001807 Urea-formaldehyde Polymers 0.000 description 2
- 235000012211 aluminium silicate Nutrition 0.000 description 2
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 2
- 239000006229 carbon black Substances 0.000 description 2
- 239000001913 cellulose Substances 0.000 description 2
- 229920002678 cellulose Polymers 0.000 description 2
- 229920001577 copolymer Polymers 0.000 description 2
- 238000004132 cross linking Methods 0.000 description 2
- 239000003431 cross linking reagent Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000004615 ingredient Substances 0.000 description 2
- 229910052500 inorganic mineral Inorganic materials 0.000 description 2
- QWTDNUCVQCZILF-UHFFFAOYSA-N isopentane Chemical compound CCC(C)C QWTDNUCVQCZILF-UHFFFAOYSA-N 0.000 description 2
- 239000002655 kraft paper Substances 0.000 description 2
- 238000010030 laminating Methods 0.000 description 2
- 239000010451 perlite Substances 0.000 description 2
- 235000019362 perlite Nutrition 0.000 description 2
- 239000005011 phenolic resin Substances 0.000 description 2
- 229920000058 polyacrylate Polymers 0.000 description 2
- 229920000728 polyester Polymers 0.000 description 2
- 229920006254 polymer film Polymers 0.000 description 2
- 238000006116 polymerization reaction Methods 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 239000003381 stabilizer Substances 0.000 description 2
- 229920001169 thermoplastic Polymers 0.000 description 2
- 239000004416 thermosoftening plastic Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- FRCHKSNAZZFGCA-UHFFFAOYSA-N 1,1-dichloro-1-fluoroethane Chemical compound CC(F)(Cl)Cl FRCHKSNAZZFGCA-UHFFFAOYSA-N 0.000 description 1
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 1
- GEHMBYLTCISYNY-UHFFFAOYSA-N Ammonium sulfamate Chemical compound [NH4+].NS([O-])(=O)=O GEHMBYLTCISYNY-UHFFFAOYSA-N 0.000 description 1
- 229920003043 Cellulose fiber Polymers 0.000 description 1
- VOPWNXZWBYDODV-UHFFFAOYSA-N Chlorodifluoromethane Chemical compound FC(F)Cl VOPWNXZWBYDODV-UHFFFAOYSA-N 0.000 description 1
- 229920002943 EPDM rubber Polymers 0.000 description 1
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 1
- 239000005977 Ethylene Substances 0.000 description 1
- 244000043261 Hevea brasiliensis Species 0.000 description 1
- 235000019738 Limestone Nutrition 0.000 description 1
- 229920001328 Polyvinylidene chloride Polymers 0.000 description 1
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 1
- YKTSYUJCYHOUJP-UHFFFAOYSA-N [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] Chemical compound [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] YKTSYUJCYHOUJP-UHFFFAOYSA-N 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 238000013019 agitation Methods 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 229910000410 antimony oxide Inorganic materials 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 239000007767 bonding agent Substances 0.000 description 1
- 239000000378 calcium silicate Substances 0.000 description 1
- 229910052918 calcium silicate Inorganic materials 0.000 description 1
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 description 1
- 238000003490 calendering Methods 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 230000001413 cellular effect Effects 0.000 description 1
- 239000003638 chemical reducing agent Substances 0.000 description 1
- 239000012792 core layer Substances 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 230000002939 deleterious effect Effects 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- AFABGHUZZDYHJO-UHFFFAOYSA-N dimethyl butane Natural products CCCC(C)C AFABGHUZZDYHJO-UHFFFAOYSA-N 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 239000000975 dye Substances 0.000 description 1
- 238000004049 embossing Methods 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 230000009969 flowable effect Effects 0.000 description 1
- 229920001821 foam rubber Polymers 0.000 description 1
- SLGWESQGEUXWJQ-UHFFFAOYSA-N formaldehyde;phenol Chemical group O=C.OC1=CC=CC=C1 SLGWESQGEUXWJQ-UHFFFAOYSA-N 0.000 description 1
- 230000004313 glare Effects 0.000 description 1
- 239000010440 gypsum Substances 0.000 description 1
- 229910052602 gypsum Inorganic materials 0.000 description 1
- DMEGYFMYUHOHGS-UHFFFAOYSA-N heptamethylene Natural products C1CCCCCC1 DMEGYFMYUHOHGS-UHFFFAOYSA-N 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- ZFSLODLOARCGLH-UHFFFAOYSA-N isocyanuric acid Chemical group OC1=NC(O)=NC(O)=N1 ZFSLODLOARCGLH-UHFFFAOYSA-N 0.000 description 1
- 239000006028 limestone Substances 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000010445 mica Substances 0.000 description 1
- 229910052618 mica group Inorganic materials 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 229920003052 natural elastomer Polymers 0.000 description 1
- 229920001194 natural rubber Polymers 0.000 description 1
- VTRUBDSFZJNXHI-UHFFFAOYSA-N oxoantimony Chemical compound [Sb]=O VTRUBDSFZJNXHI-UHFFFAOYSA-N 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 230000002085 persistent effect Effects 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 229920001084 poly(chloroprene) Polymers 0.000 description 1
- 229920001195 polyisoprene Polymers 0.000 description 1
- ODGAOXROABLFNM-UHFFFAOYSA-N polynoxylin Chemical compound O=C.NC(N)=O ODGAOXROABLFNM-UHFFFAOYSA-N 0.000 description 1
- 229920002689 polyvinyl acetate Polymers 0.000 description 1
- 239000011118 polyvinyl acetate Substances 0.000 description 1
- 239000005033 polyvinylidene chloride Substances 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 239000002243 precursor Substances 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000012744 reinforcing agent Substances 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 239000008257 shaving cream Substances 0.000 description 1
- 238000010008 shearing Methods 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 230000000087 stabilizing effect Effects 0.000 description 1
- 239000004575 stone Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
- 229920003051 synthetic elastomer Polymers 0.000 description 1
- 239000005061 synthetic rubber Substances 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 235000012222 talc Nutrition 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/587—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/78—Heat insulating elements
- E04B1/80—Heat insulating elements slab-shaped
Landscapes
- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Architecture (AREA)
- Textile Engineering (AREA)
- Acoustics & Sound (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Laminated Bodies (AREA)
- Building Environments (AREA)
- Machines For Manufacturing Corrugated Board In Mechanical Paper-Making Processes (AREA)
- Refrigerator Housings (AREA)
- Paints Or Removers (AREA)
- Finishing Walls (AREA)
- Chemical And Physical Treatments For Wood And The Like (AREA)
- Reinforced Plastic Materials (AREA)
- Compositions Of Macromolecular Compounds (AREA)
Abstract
This invention relates to a low fiber, plyable facer suitable for use in the construction industry, particularly for insulation board manufacture, comprising a dry preformed fiber mat containing a binder for the fibers, preferably a preformed glass mat, coated with a prefoamed composition which contains a thixotropic polymer latex, a foam sustaining amount of a surfactant and a flame retarding and/or strengthening amount of a mineral filler and also to the use and process for the preparation of the above as well as to a siding underlayment or insulation board having a foamed, thermosetting resin core which is surfaced with said facer as a product for commercial use.
Description
FOAMED FACER AND INSULATION BOARDS MADE THEREFROM
BACKGROUND OF THE INVENTION
Rigid polymeric foam insulation laminates have been used for many years by the construction industry. Uses include commercial roof insulation boards utilized under asphaltic built-up roof (BUR) membranes as well as under various single ply membranes such as EPDM rubber, PVC, modified bitumen membranes and the like. Other uses include residential insulation, as sheathing under siding, and as roof insulation under asphalt shingles and concrete tiles.
Such insulation often takes the form of a core polymeric foamed thermoset material such as polyurethane, polyisocyanurate, polyurethane modified polyisocyanurate (often referred to as polyiso) or phenolic resin, applied between two facing sheets.
These insulation boards are generally manufactured on production lines where a liquid core chemical mixture is poured over a bottom facer, foaming up to contact a top facer in a constrained rise laminator. The reaction of the chemical mixture causing foaming is generally exotherinic, as curing via polymerization and crosslinking occurs in the laminator. In the case of polyisocyanurate insulation boards, the curing exotherm lasts well into the time the resulting rigid boards are cut, stacked and warehoused. The exotherm can continue for as long as 4 days and the mixture can reach temperatures as high as 325 F.
Desirable properties for the facers include flexibility, high tensile and tear strength and resistance to thermal degradation. Facer porosity should be low and the thickness of the facer coating should be sufficient to prevent bleed-through of the liquid chemicals prior to foaming. Additionally, facers should exhibit good adhesion to the core foam insulation and be inert to the effects of extraneous chemicals which may be present in the mixture, especially blowing agents that also behave as solvents. Blowing agents currently in use include chlorofluorocarbons like HCFC-141b and R-22 as well as hydrocarbons such as n-pentane, cyclo-pentane and iso-pentane.
One problem that has plagued the polyiso industry has been a phenomenon called "cold temperature delamination". This phenomenon occurs in cold temperature areas where insulation boards coming off the production line cool before they can be "stack cured".
In a worst case scenario, the polyiso core foam layer closest to the facer cools, quenching the cure reaction and leaving a brittle layer. This often leads to shearing of the core layer or facer peal off. It has been the practice of manufacturers to place a layer of corrugated cardboard over both the top facer surface of the top board and under the bottom facer surface of the bottom board in the stack, to retain exothermic heat and prevent subsequent delamination. Thus, a facer that inherently insulates and retains heat during stack cure would materially reduce incidents of cold temperature delamination and would eliminate the need for costly cardboard insulation.
After these foamed polymer insulation boards are cured, cut and shipped to their use site, the facer should provide mechanical stability as well as water and weather resistance since, upon installation, they may be exposed to persistent rain, high humidity, ultraviolet light and excessive heat. Additionally, the facers must be puncture and scuff resistant to survive being nailed and walked on. Withstanding temperatures up to 500 F, as encountered in hot asphalt applications, as well as resistance to the deleterious effects of adhesive solvents used in single ply roofing membrane applications while strongly bonding to the adhesives themselves are also important facer properties.
Traditionally, facer materials have included asphalt saturated cellulosic felts, fiberglass mats, asphalt emulsion coated fiberglass mats, aluminum foil/Kraft/foil, glass fiber modified cellulosic felts, glass mats onto which polymeric films have been extruded, and glass mats coated with polymeric latex/inorganic binder coatings. However, all of these materials have at least one undesirable property. For example, asphalt-containing products are not compatible with PVC single ply roofing membranes. Fiberglass mats are subject to excessive bleed-through of foamable core chemicals.
BACKGROUND OF THE INVENTION
Rigid polymeric foam insulation laminates have been used for many years by the construction industry. Uses include commercial roof insulation boards utilized under asphaltic built-up roof (BUR) membranes as well as under various single ply membranes such as EPDM rubber, PVC, modified bitumen membranes and the like. Other uses include residential insulation, as sheathing under siding, and as roof insulation under asphalt shingles and concrete tiles.
Such insulation often takes the form of a core polymeric foamed thermoset material such as polyurethane, polyisocyanurate, polyurethane modified polyisocyanurate (often referred to as polyiso) or phenolic resin, applied between two facing sheets.
These insulation boards are generally manufactured on production lines where a liquid core chemical mixture is poured over a bottom facer, foaming up to contact a top facer in a constrained rise laminator. The reaction of the chemical mixture causing foaming is generally exotherinic, as curing via polymerization and crosslinking occurs in the laminator. In the case of polyisocyanurate insulation boards, the curing exotherm lasts well into the time the resulting rigid boards are cut, stacked and warehoused. The exotherm can continue for as long as 4 days and the mixture can reach temperatures as high as 325 F.
Desirable properties for the facers include flexibility, high tensile and tear strength and resistance to thermal degradation. Facer porosity should be low and the thickness of the facer coating should be sufficient to prevent bleed-through of the liquid chemicals prior to foaming. Additionally, facers should exhibit good adhesion to the core foam insulation and be inert to the effects of extraneous chemicals which may be present in the mixture, especially blowing agents that also behave as solvents. Blowing agents currently in use include chlorofluorocarbons like HCFC-141b and R-22 as well as hydrocarbons such as n-pentane, cyclo-pentane and iso-pentane.
One problem that has plagued the polyiso industry has been a phenomenon called "cold temperature delamination". This phenomenon occurs in cold temperature areas where insulation boards coming off the production line cool before they can be "stack cured".
In a worst case scenario, the polyiso core foam layer closest to the facer cools, quenching the cure reaction and leaving a brittle layer. This often leads to shearing of the core layer or facer peal off. It has been the practice of manufacturers to place a layer of corrugated cardboard over both the top facer surface of the top board and under the bottom facer surface of the bottom board in the stack, to retain exothermic heat and prevent subsequent delamination. Thus, a facer that inherently insulates and retains heat during stack cure would materially reduce incidents of cold temperature delamination and would eliminate the need for costly cardboard insulation.
After these foamed polymer insulation boards are cured, cut and shipped to their use site, the facer should provide mechanical stability as well as water and weather resistance since, upon installation, they may be exposed to persistent rain, high humidity, ultraviolet light and excessive heat. Additionally, the facers must be puncture and scuff resistant to survive being nailed and walked on. Withstanding temperatures up to 500 F, as encountered in hot asphalt applications, as well as resistance to the deleterious effects of adhesive solvents used in single ply roofing membrane applications while strongly bonding to the adhesives themselves are also important facer properties.
Traditionally, facer materials have included asphalt saturated cellulosic felts, fiberglass mats, asphalt emulsion coated fiberglass mats, aluminum foil/Kraft/foil, glass fiber modified cellulosic felts, glass mats onto which polymeric films have been extruded, and glass mats coated with polymeric latex/inorganic binder coatings. However, all of these materials have at least one undesirable property. For example, asphalt-containing products are not compatible with PVC single ply roofing membranes. Fiberglass mats are subject to excessive bleed-through of foamable core chemicals.
Aluminum facers and foils reflect heat into the foam during processing which leads to disruption of cell structure, delamination and warping. Further, foil faced sheathing and extrusion or lamination of a polymer film to glass mat surfaces are costly. Specifically, glass mats coated with polymer latex/inorganic binder mixtures have been found to be brittle; conversely, glass fiber modified cellulosic felts are susceptible to moisture absorption aggravating board warping in damp or wet environments.
Other facers which have been employed for siding underlayment and insulation board facers include those disclosed in U.S. Patents 5,776,841 and 5,717,012, which are primarily felts.
U.S. Patent No. 5,001,005 describes a facing sheet composed of glass fibers and a non-asphaltic binder. The facer contains 60-90% glass fibers, which high fiber content does not provide sufficient binder to close the sheet's pores or to provide desired sheet strength. U.S.
Patent No. 5,102,728, describing a glass mat substrate coated with a polymeric latex blended with an asphalt emulsion, concerns a product which is not only incompatible with PVC roofing membranes but also requires excessive coating thicknesses to reduce high porosity.
Accordingly, this product is very costly. U.S. Patent No. 5,112,678 discloses a facer prepared by applying to a fiberglass mat a flowable polymer latex and an inorganic binder coating. The resulting product is somewhat brittle and is susceptible to an undesirable degree of chemical bleed through. U.S. Patent Nos. 5,698,302 and 5,698,304 describe facers where polymer films are laminated or extruded onto fiberglass mat. Not only is this approach costly, but also since conventional mineral flame retardant filled polymers do not extrude well, some degree of resistance to flammability must be sacrificed.
This invention overcomes or at least mitigates the above disadvantages and deficiencies and provides a facer which is economically produced by a commercially feasible process.
The invention provides a mechanically stable facer suitable for insulation board manufacture which resists cold temperature delamination and which has superior tolerance to the effects of weathering.
The invention also provides a facer which exhibits superior adhesion to polyiso foam of an insulation board core material.
The non-asphaltic, non-cellulosic facer of the present invention comprises a dry, preformed fibrous mat substrate on which is coated a pre-frothed or pre-foamed composition containing a natural or synthetic thixotropic latex polymer, a surfactant and an inorganic mineral filler.
The composition may optionally contain up to about 15 wt.%
of extraneous additives, which include a flame retardant, dye, thickener, porosity reducing agent, thermal and/or W
stabilizers and the like, to provide a foamed facer product having, on a dry weight basis, less than 50% fiber in the mat. The preferred facer product contains 30 to 46 wt.o of fiber in the composition consisting of mat fiber with binder and latex in the coating mixture.
Other facers which have been employed for siding underlayment and insulation board facers include those disclosed in U.S. Patents 5,776,841 and 5,717,012, which are primarily felts.
U.S. Patent No. 5,001,005 describes a facing sheet composed of glass fibers and a non-asphaltic binder. The facer contains 60-90% glass fibers, which high fiber content does not provide sufficient binder to close the sheet's pores or to provide desired sheet strength. U.S.
Patent No. 5,102,728, describing a glass mat substrate coated with a polymeric latex blended with an asphalt emulsion, concerns a product which is not only incompatible with PVC roofing membranes but also requires excessive coating thicknesses to reduce high porosity.
Accordingly, this product is very costly. U.S. Patent No. 5,112,678 discloses a facer prepared by applying to a fiberglass mat a flowable polymer latex and an inorganic binder coating. The resulting product is somewhat brittle and is susceptible to an undesirable degree of chemical bleed through. U.S. Patent Nos. 5,698,302 and 5,698,304 describe facers where polymer films are laminated or extruded onto fiberglass mat. Not only is this approach costly, but also since conventional mineral flame retardant filled polymers do not extrude well, some degree of resistance to flammability must be sacrificed.
This invention overcomes or at least mitigates the above disadvantages and deficiencies and provides a facer which is economically produced by a commercially feasible process.
The invention provides a mechanically stable facer suitable for insulation board manufacture which resists cold temperature delamination and which has superior tolerance to the effects of weathering.
The invention also provides a facer which exhibits superior adhesion to polyiso foam of an insulation board core material.
The non-asphaltic, non-cellulosic facer of the present invention comprises a dry, preformed fibrous mat substrate on which is coated a pre-frothed or pre-foamed composition containing a natural or synthetic thixotropic latex polymer, a surfactant and an inorganic mineral filler.
The composition may optionally contain up to about 15 wt.%
of extraneous additives, which include a flame retardant, dye, thickener, porosity reducing agent, thermal and/or W
stabilizers and the like, to provide a foamed facer product having, on a dry weight basis, less than 50% fiber in the mat. The preferred facer product contains 30 to 46 wt.o of fiber in the composition consisting of mat fiber with binder and latex in the coating mixture.
In one aspect, the invention provides a flexible, low fiber containing facer suitable for use in building construction and containing less than 50 wtA fiber, which comprises a non-asphaltic, non-cellulosic fiber mat substrate of between about 10 and about 30 mils thickness in contact with a 5 to 100 mil thick mat surface coating of between about 15 and about 80 wtA of a foamed mixture containing, on a dry weight basis, (a) between about 15 and about 80 wt.% of a thixotropic polymer latex, (b) a strengthening or fire retarding amount of between about 0.01 and about 80 wt.% of an inorganic filler and (c) a foam building, foam sustaining amount of between about 0.5 and about 10 wt.% of an organic surfactant.
In a further aspect, the invention provides a process for preparing the facer of the invention, which comprises: (i) forming a 15 to 80 wt.o aqueous mixture of (a), (b) and (c); (ii) foaming the mixture from (i) to a self-sustaining consistency; (iii) applying a 5 to 80 mil uniform coating of the foamed mixture from (ii) to one surface of said mat; (iv) drying the resulting mat; and (v) recovering the dried, foam coated mat having a fiber concentration below 50 wt.o as a product of the process.
The invention also provides insulation boards having a non-elastic core laminated on one or both surfaces to a facer of the invention.
These and other aspects and advantages of the invention will become apparent from the following description and disclosure.
DETAILED DESCRIPTION OF THE INVENTION
Generally, the foamed coating composition applied to the preformed mat contains on a dry weight basis between 6a about 15 and about 80 wt.% of the thixotropic polymer latex, between 0.01 and about 80 wt.W filler, between about 0.5 and about 10 wt.s foam supporting surfactant and 0 to 15 wt.o extraneous additives.
The fibers of the mat employed in this invention include any of the non-cellulosic types, such as fibers of glass, polyester, polypropylene, polyester/polyethylene/teraphthalate copolymers, hybrid types such as polyethylene/glass fibers and other conventional non-cellulosic fibers. Mats having glass fibers in random orientation are preferred for their resistance to heat generated during the manufacture of insulation boards and flame resistance in the finished product.
The fibrous mats of the invention, generally of between about 10 and about 30 mils thickness, conventionally contain a binder which is incorporated during mat formation to fix the fibers in a self-sustaining solid web and to prevent loss of fibers during subsequent processing and handling. Such binders include phenol-, melamine- and/or urea-formaldehyde resins or mixtures thereof. Most preferred are the mats having glass fibers in the range of from about 3 to about 20 microns, most desirably 10-18 microns, in diameter and a length of from about 0.25 to about 1.75 inch, most desirably a length of 0.75-1.5 inch.
The fillers useful in the present coating mixture include conventional inorganic types such as clays, mica, talc, limestone, kaolin, other stone dusts, gypsum, aluminum silicate (e . g. Ecca Tex TM 561), flame retardant aluminum trihydrate, ammonium sulfamate, antimony oxide, calcium silicate, calcium sulfate, and mixtures thereof.
Surfactants employed in the coating composition are organic types suitable for stabilizing latices, such as for example, ammonium salts of a C10 to C22 fatty acid, e.g. ammonium stearate (STANF~~T" .320). One or more surfactants can be employed in the coating composition to promote the formation of foam and to maintain the foam structure of the coating before curing.
The latex component of the coating composition includes latex polymers of natural rubber as well as synthetic latices including copolymers of styrene and butadiene and acrylic based resins. Representative examples of these are polyvinyl chloride, styrene/acrylic or znethacrylic esters, ethylene/vinyl chloride and polyurethane, polyisoprene, polyvinylidene chloride, polyvinyl acetate/polyvinyl chloride and synthetic rubbers such as SBS, SBR, neoprene, etc. and any other thixotropic latex polymer and mixtures of the foregoing.
The mat coating mixture of the invention is obtained from a frothed or foamed 15-80 wt.% aqueous emulsion, dispersion or suspension, which is prefoamed by incorporating air in the aqueous liquid mixture, e.g, by blowing or mixing, with vigorous agitation in the presence or absence of a conventional blowing agent. The resulting frothed or foamed, aerated composition is then coated to a thickness of from about 5 to about 100 mils on the preformed mat surface under ambient conditions using a knife blade, a roller or any other convenient method of application. In one aspect, the foam coated mat is then dried at below its cure temperature to provide a foamed, self-supporting product having a reduced coating thickness of up to 90 mils which adheres to the mat surface. In another aspect, the foamed coated mat is dried and cured simultaneously.
The resulting facer product of this invention is desirably flexible and possesses low permability to liquid chemicals used for insulation cores as well as superior dimensional stability and high tensile strength after curing. This product, comprising the mat having an adhered surface coating of a prefoamed latex/filler/surfactant, can be fed directly to insulation board manufacture, e.g. a constricted rise laminator, wherein the uncoated fiber surface of the mat contacts at least one exposed surface of a foamed or foamable thermosetting non-elastomeric core in the manufacture of an insulation board as described hereinaf ter .
As indicated above, the foamed coating of the present facer can be formed in the absence or presence of a blowing agent to provide a composition of reduced density, which density can be reduced from above about 2 g/cc, e.g. 4 g/cc, to as little as 0.1 g/cc.
Advantageously, the consistency of the foam is such that the coating mixture does not penetrate through the mat and ideally simulates the consistency of shaving cream.
Generally the amount of air incorporated into the foamable mixture prior to coating is between about 5% and about 80% by volume for optimal consistency and the resulting foamed mixture has bubble openings sufficiently small so as to inhibit liquid bleed through the mat.
Applying a film or laminating a layer of impervious resin or polymer over the foamed surface to provide a trilayered facer member can provide a totally liquid impervious surface on the facer, in special cases where such is desired. A top seal coat of a non-foamed latex is suitable for this purpose. Alternatively, a thermoplastic such as polyethylene powder or unexpanded polystyrene beads can be used as a filler which melts at the drying/curing temperatures to close substantially all pores of the pervious coating. Expandable excipients and additives such as cellulose can also be used for this purpose; although the use of a seal coat is neither needed nor recommended. Other methods for accomplishing the similar purpose include the use of less air during foaming, the omission or use of less inorganic filler in the coating composition, calendering and/or embossing the foamed or frothed surface by contact with a hot roller or platen. Still another method for producing the totally impervious surface involves forming the foam on the smooth surface of a conventional release material and then contacting the mat with the opposite surface of the foam. A combination of any of the above options can be employed for specialized purposes if desired.
In the present case, the facer of the invention having a foamed cellular coating, contains latent exothermic energy and has a higher potential heat capacity upon entering the laminator; thus lowering the lamination cure time and prolonging the generation of heat by acting as an insulator during curing in the post cure stack. This advantage eliminates the need for heat retaining members at the top and bottom of the stack and significantly reduces the prior problem of the board's susceptibility to cold temperature delamination.
Additionally, where the foamed coating on the facer is dried and/or cured, the bonding strength between the uncoated fibers and the core material in the resulting product is enhanced due to reduced penetration of the coating mixture into the mat by reason of its prefoamed state. Where the foam of the facer is completely cured before entering the laminator, the core material is either poured onto the uncoated fibrous surface of the facer or laminated thereto with adhesive or bonding agent.
Any pressure which may be applied during lamination in the insulation board manufacture is less than that required to cause a 50% reduction in the thickness of the foamed facer coating and insufficient to result in damage or crushing of the mat fibers in the finished insulation board product.
The weight of the present facer can vary from about 40 to about 300 g/sq. meter and the foamed facer sheet can have a thickness up to about 100 mils depending on the preference of the consumer. For certain purposes demanding tougher facers, laticies which can be crosslinked can be selected.
The present latex coating composition may additionally contain a minor amount,.up to 15%, preferably less than about 3 wt. %, of a conventional thickening agent, for example an acrylic polymer thickener, e.g. (ACRYSOL'"A ASE 95NP and/or 60 NP) and the like. Other inert excipients such as a LTV or thermal stabilizer, a conventional coloring agent, texturizina agent, reinforcing or crosslinking agent, (e.g. CYMELTM 303 resin) and/or blowing agent may also be included in the coating mixture; although addition of these additives in a minor amount of less than 2 wt.% are preferred.
The insulation boards, for which the present facer is particularly suited, comprise conventional thermosetting or thermoplastic foam cores, such as foamed polyurethane or polyurethane modified polyisocyanurate or phenol-formaldehyde cores disposed between a pair of facer members which are laminated to the core surfaces.
Other non-elastomeric foamable chemicals, such as polyvinyl chloride, polystyrene, polyethylene, polypropylene, and others conventionally employed as core material can also be employed as the insulation board core of this invention. Rigid foamed cores of this type are described for example in U. S. Patent 4,351,873.
The present facers are also suitable for sheathing a siding underlayment generally of a thickness up to about 1 inch and composed of a non-elastic core material of a chemical or chemical mixture similar to that of the insulation core. The use of instant facer eliminates the need for expensive foil facings which hold and reflect heat and often cause warping and deterioration of wood overlayment. Also, foil and similar facings are easily punctured which gives rise to moisture attack.
In the insulation manufacture, a roll of the present foamed facer sheet product is passed, with its uncoated fiber surface opposite the core surface, to a laminating zone. The board core foam precursor chemical or mixture of chemicals can be poured onto the non-coated fiber surface of the facer sheet or the core of the insulation board can be prefoamed to a self-sustaining consistency.
In one embodiment, a first facer of this invention, with its uncoated surface abutting the core, is placed below the core. The fiber surface of a second facer is positioned and spaced above the core to allow for core expansion, e.g. in a constricted rise laminator, where the assembly undergoes an exothermic reaction and curing is initiated. During the curing operation the core material foams and rises to engage the lower uncoated surface of the second facer. It is to be understood that one of the first and second facers can be of the same or of a different composition than that of this invention;
although it is preferred that both of these facers be those of the invention described herein. More specifically, one of the facer sheets may be selected from those conventionally employed, such as for example a cellulose or cellulose-glass hybrid felt sheet, perlite, aluminum foil, multilaminated sheets of foil and Kraft, uncoated or coated fiber glass mats; although the second facer sheet of the present invention enhances the advantages described herein. As the core foam is spread on the fibrous surface of the first facer sheet entering the laminator, it undergoes an exothermic reaction which can attain a temperature up to about 200 F. The core foam rises to contact the undersurface of the second facer and hardens thereon; thus providing a rigid insulating foam core interposed or sandwiched between two facer sheets. The resulting product can then be cut into boards of desired size and shape. The heat of the exothermic reaction involving polymerization and/or crosslinking, is autogenerated in both the laminator and in the subsequent stacking of insulation boards to insure complete curing of the core and surface coating of the facer. Curing temperatures during stacking can rise up to about 325 F over a period of up to 4 days.
As another embodiment involving the above operation, the top and bottom positioning of the facer sheets can be reversed so that the facer of this invention is fed and spaced above a conventional facer in a manner such that its non-coated fibrous surface faces the foamable insulating core chemical being contacted on its under surface with another facer sheet. The later procedure is practiced where one facer is a rigid sheet, as in a perlite or particle board facer as opposed to the flexible facer of this invention which can be fed to the laminator as a continuous roll. In this case the foamable insulating core chemical is surfaced on the rigid facer member and rises to engage the fibrous uncoated surface of the present facer.
The latex of the present facer surface layer which, due to its comparatively thick latex foam, and low fiber to coating latex ratio, more efficiently retains heat between the layers of the roll. Hence, lamination of the core can be completed at a faster rate and stacking accomplished without damage to the laminate.
Additionally, it is now found that this retention of heat during curing improves core bonding and significantly reduces subsequent "cold temperature delamination" in the product, which is caused by failure of the top layer of insulation to completely cure due to cooler temperature exposure during stacking after leaving the laminator.
The insulation boards incorporating the present facers are useful in commercial roof insulation, residential or commercial wall sheathing etc. Depending upon the intended use, the present insulation board has a core thickness which may vary widely, for example between about 0.5 and about 4 inches or more.
In the above discussion, it will become apparent that it is also possible to form the insulation core separately, i.e. absent contact with the fibers of a facer, and subsequently bond one or more of the present facers to the core using suitable adhesives. In general, the teachings of U.S. Patent 4,351,873 are applicable to the formation of rigid foam cores and adhesion of facer sheets to at least one surface of such cores.
Polyurethane or polyisocyanurate are most commonly employed as core materials; although other non-elastomeric, foamable chemicals are also employed.
Examples of the later include polyvinyl chloride, polystyrene, phenolic resins and the like.
The facers and the insulation board products of this invention exhibit significantly higher tensile strength than those containing 60-90 wt.% fibers. The present facer.s also possess resistance to cracking at low temperatures and exceptionally superior dimensional stability and flame retardance. Because of their superior strength and flexibility, the present facer can find broader application, such as non-foil, non-glare sheathings, as shingle underlayment, separation or barrier sheets and the like.
A 473 ml metal can with a low shear mixer was employed to combine a 51.5 % aqueous solution of a self crosslinkable acrylic latex (Rohm & Haas, E-693), a 23.5%
agueous clay slurry (Ecca Tex 561), a mixture of a melamine crosslinking agent (CYMEL 303), an ammonium stearate foam stabilizer (STANFAIi 320), an acrylic polymer thickening agent (Acrysal ASE 95NP) and carbon black pigment in amounts shown in following Table 1. The above ingredients were thoroughly mixed for about 10 minutes and then foamed using a high speed Kitchen Aid"
mixer to produce a foam having a density of 0.2 g./cc.
The Brookfield viscosity of the foamed mixture, using an LVT #4 spindle at 30 rpm, was 1,500 cps.
INGREDIENT ~ Solids Parts Parts Wet Basis Dry Basis Acrylic latex 48.5 100 48.50 Kaolin slurry 76.5 90 68.85 CYMEL 303 100 1.5 1.50 STANFAX 320* 33 8.0 2.64 Acrysol ASE 95NP
Water (1/1 mole) 9.3 0.8 0.07 Carbon black 33 0.45 0.15 * ammonium stearate The above foamed latex mixture was coated onto the upper surface of a preformed glass fiber mat containing 27.5 wtA urea-formaldehyde binder and having 72.5 wt.%
of average 114 inch long filaments of 15.9 micron average diameter. Coating was accomplished using a Gardner draw-down gauge set to achieve a coating thickness of 30 mils on the mat. The resulting sample was dried in an oven at 125 C. for 3 minutes and then cured at 150 C. for an additional 3 minutes.
The properties of above facer sample was compared with those of commercial samples A, B and C. and the results were as recorded in Table 2.
Example 1 was repeated except that self-. ...
crosslinkable acrylic (RHOPLEX"" B-959) was substituted for latex (E-693) and the dried prefoamed mixture on the mat was not cured. The unfoamed mixture of this example had a Brookfield viscosity of 3,600 cps.
The uncured, foam-coated mat of this example was introduced to a laminator wherein the uncoated fiber under surface of the mat was contacted with a foamed polyurethane/isocyanurate core of an insulation board and the simultaneous curing of the mat foam and the core was initiated. After about 1-2 minutes in the laminator, at a temperature of about 120 to 200 C, the laminated board was cut into 4 x 8 foot boards and the boards squares stacked in units of 25 members to complete curing over a period of 2.5 days.
Example 1 was repeated except that an additional 45 g of aluminum trihydrate (ALCOA GRADE C-320) was added to the coating mixture to increase flame retardance of the facer. The Brookfield viscosity of the unfoamed mixture was 2,200 cps and the foam had a density of 0.23 g/cc.
Conventional facers most commonly employed are non-coated, cellulose fiber mats which may or may not be reinforced with a minor amount of glass fibers. In Table 2, Examples A and B represent this type. Example A is reinforced with 18% of 114 inch long glass fibers, Example B is reinforced with 13% of less than 1/8 inch long glass fibers.
Another type of facer which has had commercial success comprises a glass mat on which a polyethylene coating has been extruded. A facer of this type is represented as Sample C.
The properties of all of the facers in the above examples are reported in following Table 2.
~
~
.,~
O N ~'~1 m V r.{ (n m f~1 1 1 I I I I
[~ '-1 ~-1 t0 N1 1 I I I I I
(O~
U
ri ~0 .,~
V O OD ~O O O
~N (A N OD O N [~ ~1 ~O [~ ~ ~
~ N ~==1 01 d' r=1 r1 ~=-I N O~-i O
U
~
N
.,~
~ to CD ~c1 m IA .~-1 tOo ~ ,~', 01 OD O Orn m c~1 rn O
e-1 ~==1 a~ N.-1 N f~1 N1 O O
O
U
~+1 N O
r N [~ d N N N
~ ~ . .
H ~ If! tl1 Lf1 In O C~D f~ I O O
W .-1 f+~1 P'1 V~ c+l (*1 sT 1 O O
N
m /-~I
q ri t0 ~O '-1 N N
Id [~ aD I O O
k M 1f1 .-I d fn m rl I
W ri f~'1 d' rP f*1 C~1 t11 I O O
~-i m ~
~ ~ ~ ~~ O!` 00 M. n') t[1 r=1 ul s! 01 111 O
yr~ r 1 (+r1 d' d V f+) V~ t0 O O
1~
~ ~ ~~
w tn =~ o ,"~ w ~rl ~
~ `~ u ~ ~i .v o b~ 0 1~1 rn ~4 J=~ A
~i ~" ,ai ~ N ~ N r +1 ~ O
~ tn ~ .~-1 a~i ~ A W ~ (~ ~ ~ a~~+i ~j ~ 1 ~ ~ I .F ~ O C) A .ti (~ ~ .Oi 1~ ~i U
f~ ~o mA d ~~A Tl 0 O m a ' ~\ p' ~ A ai ~~ m o~ ~-oi ai w a c~~ c`~~~ aw H~~ w b+~ ~ A~=
The above examples are representative and it will. be understood that many alterations and substitutions can be made therein without departing from the scope of this invention.
In a further aspect, the invention provides a process for preparing the facer of the invention, which comprises: (i) forming a 15 to 80 wt.o aqueous mixture of (a), (b) and (c); (ii) foaming the mixture from (i) to a self-sustaining consistency; (iii) applying a 5 to 80 mil uniform coating of the foamed mixture from (ii) to one surface of said mat; (iv) drying the resulting mat; and (v) recovering the dried, foam coated mat having a fiber concentration below 50 wt.o as a product of the process.
The invention also provides insulation boards having a non-elastic core laminated on one or both surfaces to a facer of the invention.
These and other aspects and advantages of the invention will become apparent from the following description and disclosure.
DETAILED DESCRIPTION OF THE INVENTION
Generally, the foamed coating composition applied to the preformed mat contains on a dry weight basis between 6a about 15 and about 80 wt.% of the thixotropic polymer latex, between 0.01 and about 80 wt.W filler, between about 0.5 and about 10 wt.s foam supporting surfactant and 0 to 15 wt.o extraneous additives.
The fibers of the mat employed in this invention include any of the non-cellulosic types, such as fibers of glass, polyester, polypropylene, polyester/polyethylene/teraphthalate copolymers, hybrid types such as polyethylene/glass fibers and other conventional non-cellulosic fibers. Mats having glass fibers in random orientation are preferred for their resistance to heat generated during the manufacture of insulation boards and flame resistance in the finished product.
The fibrous mats of the invention, generally of between about 10 and about 30 mils thickness, conventionally contain a binder which is incorporated during mat formation to fix the fibers in a self-sustaining solid web and to prevent loss of fibers during subsequent processing and handling. Such binders include phenol-, melamine- and/or urea-formaldehyde resins or mixtures thereof. Most preferred are the mats having glass fibers in the range of from about 3 to about 20 microns, most desirably 10-18 microns, in diameter and a length of from about 0.25 to about 1.75 inch, most desirably a length of 0.75-1.5 inch.
The fillers useful in the present coating mixture include conventional inorganic types such as clays, mica, talc, limestone, kaolin, other stone dusts, gypsum, aluminum silicate (e . g. Ecca Tex TM 561), flame retardant aluminum trihydrate, ammonium sulfamate, antimony oxide, calcium silicate, calcium sulfate, and mixtures thereof.
Surfactants employed in the coating composition are organic types suitable for stabilizing latices, such as for example, ammonium salts of a C10 to C22 fatty acid, e.g. ammonium stearate (STANF~~T" .320). One or more surfactants can be employed in the coating composition to promote the formation of foam and to maintain the foam structure of the coating before curing.
The latex component of the coating composition includes latex polymers of natural rubber as well as synthetic latices including copolymers of styrene and butadiene and acrylic based resins. Representative examples of these are polyvinyl chloride, styrene/acrylic or znethacrylic esters, ethylene/vinyl chloride and polyurethane, polyisoprene, polyvinylidene chloride, polyvinyl acetate/polyvinyl chloride and synthetic rubbers such as SBS, SBR, neoprene, etc. and any other thixotropic latex polymer and mixtures of the foregoing.
The mat coating mixture of the invention is obtained from a frothed or foamed 15-80 wt.% aqueous emulsion, dispersion or suspension, which is prefoamed by incorporating air in the aqueous liquid mixture, e.g, by blowing or mixing, with vigorous agitation in the presence or absence of a conventional blowing agent. The resulting frothed or foamed, aerated composition is then coated to a thickness of from about 5 to about 100 mils on the preformed mat surface under ambient conditions using a knife blade, a roller or any other convenient method of application. In one aspect, the foam coated mat is then dried at below its cure temperature to provide a foamed, self-supporting product having a reduced coating thickness of up to 90 mils which adheres to the mat surface. In another aspect, the foamed coated mat is dried and cured simultaneously.
The resulting facer product of this invention is desirably flexible and possesses low permability to liquid chemicals used for insulation cores as well as superior dimensional stability and high tensile strength after curing. This product, comprising the mat having an adhered surface coating of a prefoamed latex/filler/surfactant, can be fed directly to insulation board manufacture, e.g. a constricted rise laminator, wherein the uncoated fiber surface of the mat contacts at least one exposed surface of a foamed or foamable thermosetting non-elastomeric core in the manufacture of an insulation board as described hereinaf ter .
As indicated above, the foamed coating of the present facer can be formed in the absence or presence of a blowing agent to provide a composition of reduced density, which density can be reduced from above about 2 g/cc, e.g. 4 g/cc, to as little as 0.1 g/cc.
Advantageously, the consistency of the foam is such that the coating mixture does not penetrate through the mat and ideally simulates the consistency of shaving cream.
Generally the amount of air incorporated into the foamable mixture prior to coating is between about 5% and about 80% by volume for optimal consistency and the resulting foamed mixture has bubble openings sufficiently small so as to inhibit liquid bleed through the mat.
Applying a film or laminating a layer of impervious resin or polymer over the foamed surface to provide a trilayered facer member can provide a totally liquid impervious surface on the facer, in special cases where such is desired. A top seal coat of a non-foamed latex is suitable for this purpose. Alternatively, a thermoplastic such as polyethylene powder or unexpanded polystyrene beads can be used as a filler which melts at the drying/curing temperatures to close substantially all pores of the pervious coating. Expandable excipients and additives such as cellulose can also be used for this purpose; although the use of a seal coat is neither needed nor recommended. Other methods for accomplishing the similar purpose include the use of less air during foaming, the omission or use of less inorganic filler in the coating composition, calendering and/or embossing the foamed or frothed surface by contact with a hot roller or platen. Still another method for producing the totally impervious surface involves forming the foam on the smooth surface of a conventional release material and then contacting the mat with the opposite surface of the foam. A combination of any of the above options can be employed for specialized purposes if desired.
In the present case, the facer of the invention having a foamed cellular coating, contains latent exothermic energy and has a higher potential heat capacity upon entering the laminator; thus lowering the lamination cure time and prolonging the generation of heat by acting as an insulator during curing in the post cure stack. This advantage eliminates the need for heat retaining members at the top and bottom of the stack and significantly reduces the prior problem of the board's susceptibility to cold temperature delamination.
Additionally, where the foamed coating on the facer is dried and/or cured, the bonding strength between the uncoated fibers and the core material in the resulting product is enhanced due to reduced penetration of the coating mixture into the mat by reason of its prefoamed state. Where the foam of the facer is completely cured before entering the laminator, the core material is either poured onto the uncoated fibrous surface of the facer or laminated thereto with adhesive or bonding agent.
Any pressure which may be applied during lamination in the insulation board manufacture is less than that required to cause a 50% reduction in the thickness of the foamed facer coating and insufficient to result in damage or crushing of the mat fibers in the finished insulation board product.
The weight of the present facer can vary from about 40 to about 300 g/sq. meter and the foamed facer sheet can have a thickness up to about 100 mils depending on the preference of the consumer. For certain purposes demanding tougher facers, laticies which can be crosslinked can be selected.
The present latex coating composition may additionally contain a minor amount,.up to 15%, preferably less than about 3 wt. %, of a conventional thickening agent, for example an acrylic polymer thickener, e.g. (ACRYSOL'"A ASE 95NP and/or 60 NP) and the like. Other inert excipients such as a LTV or thermal stabilizer, a conventional coloring agent, texturizina agent, reinforcing or crosslinking agent, (e.g. CYMELTM 303 resin) and/or blowing agent may also be included in the coating mixture; although addition of these additives in a minor amount of less than 2 wt.% are preferred.
The insulation boards, for which the present facer is particularly suited, comprise conventional thermosetting or thermoplastic foam cores, such as foamed polyurethane or polyurethane modified polyisocyanurate or phenol-formaldehyde cores disposed between a pair of facer members which are laminated to the core surfaces.
Other non-elastomeric foamable chemicals, such as polyvinyl chloride, polystyrene, polyethylene, polypropylene, and others conventionally employed as core material can also be employed as the insulation board core of this invention. Rigid foamed cores of this type are described for example in U. S. Patent 4,351,873.
The present facers are also suitable for sheathing a siding underlayment generally of a thickness up to about 1 inch and composed of a non-elastic core material of a chemical or chemical mixture similar to that of the insulation core. The use of instant facer eliminates the need for expensive foil facings which hold and reflect heat and often cause warping and deterioration of wood overlayment. Also, foil and similar facings are easily punctured which gives rise to moisture attack.
In the insulation manufacture, a roll of the present foamed facer sheet product is passed, with its uncoated fiber surface opposite the core surface, to a laminating zone. The board core foam precursor chemical or mixture of chemicals can be poured onto the non-coated fiber surface of the facer sheet or the core of the insulation board can be prefoamed to a self-sustaining consistency.
In one embodiment, a first facer of this invention, with its uncoated surface abutting the core, is placed below the core. The fiber surface of a second facer is positioned and spaced above the core to allow for core expansion, e.g. in a constricted rise laminator, where the assembly undergoes an exothermic reaction and curing is initiated. During the curing operation the core material foams and rises to engage the lower uncoated surface of the second facer. It is to be understood that one of the first and second facers can be of the same or of a different composition than that of this invention;
although it is preferred that both of these facers be those of the invention described herein. More specifically, one of the facer sheets may be selected from those conventionally employed, such as for example a cellulose or cellulose-glass hybrid felt sheet, perlite, aluminum foil, multilaminated sheets of foil and Kraft, uncoated or coated fiber glass mats; although the second facer sheet of the present invention enhances the advantages described herein. As the core foam is spread on the fibrous surface of the first facer sheet entering the laminator, it undergoes an exothermic reaction which can attain a temperature up to about 200 F. The core foam rises to contact the undersurface of the second facer and hardens thereon; thus providing a rigid insulating foam core interposed or sandwiched between two facer sheets. The resulting product can then be cut into boards of desired size and shape. The heat of the exothermic reaction involving polymerization and/or crosslinking, is autogenerated in both the laminator and in the subsequent stacking of insulation boards to insure complete curing of the core and surface coating of the facer. Curing temperatures during stacking can rise up to about 325 F over a period of up to 4 days.
As another embodiment involving the above operation, the top and bottom positioning of the facer sheets can be reversed so that the facer of this invention is fed and spaced above a conventional facer in a manner such that its non-coated fibrous surface faces the foamable insulating core chemical being contacted on its under surface with another facer sheet. The later procedure is practiced where one facer is a rigid sheet, as in a perlite or particle board facer as opposed to the flexible facer of this invention which can be fed to the laminator as a continuous roll. In this case the foamable insulating core chemical is surfaced on the rigid facer member and rises to engage the fibrous uncoated surface of the present facer.
The latex of the present facer surface layer which, due to its comparatively thick latex foam, and low fiber to coating latex ratio, more efficiently retains heat between the layers of the roll. Hence, lamination of the core can be completed at a faster rate and stacking accomplished without damage to the laminate.
Additionally, it is now found that this retention of heat during curing improves core bonding and significantly reduces subsequent "cold temperature delamination" in the product, which is caused by failure of the top layer of insulation to completely cure due to cooler temperature exposure during stacking after leaving the laminator.
The insulation boards incorporating the present facers are useful in commercial roof insulation, residential or commercial wall sheathing etc. Depending upon the intended use, the present insulation board has a core thickness which may vary widely, for example between about 0.5 and about 4 inches or more.
In the above discussion, it will become apparent that it is also possible to form the insulation core separately, i.e. absent contact with the fibers of a facer, and subsequently bond one or more of the present facers to the core using suitable adhesives. In general, the teachings of U.S. Patent 4,351,873 are applicable to the formation of rigid foam cores and adhesion of facer sheets to at least one surface of such cores.
Polyurethane or polyisocyanurate are most commonly employed as core materials; although other non-elastomeric, foamable chemicals are also employed.
Examples of the later include polyvinyl chloride, polystyrene, phenolic resins and the like.
The facers and the insulation board products of this invention exhibit significantly higher tensile strength than those containing 60-90 wt.% fibers. The present facer.s also possess resistance to cracking at low temperatures and exceptionally superior dimensional stability and flame retardance. Because of their superior strength and flexibility, the present facer can find broader application, such as non-foil, non-glare sheathings, as shingle underlayment, separation or barrier sheets and the like.
A 473 ml metal can with a low shear mixer was employed to combine a 51.5 % aqueous solution of a self crosslinkable acrylic latex (Rohm & Haas, E-693), a 23.5%
agueous clay slurry (Ecca Tex 561), a mixture of a melamine crosslinking agent (CYMEL 303), an ammonium stearate foam stabilizer (STANFAIi 320), an acrylic polymer thickening agent (Acrysal ASE 95NP) and carbon black pigment in amounts shown in following Table 1. The above ingredients were thoroughly mixed for about 10 minutes and then foamed using a high speed Kitchen Aid"
mixer to produce a foam having a density of 0.2 g./cc.
The Brookfield viscosity of the foamed mixture, using an LVT #4 spindle at 30 rpm, was 1,500 cps.
INGREDIENT ~ Solids Parts Parts Wet Basis Dry Basis Acrylic latex 48.5 100 48.50 Kaolin slurry 76.5 90 68.85 CYMEL 303 100 1.5 1.50 STANFAX 320* 33 8.0 2.64 Acrysol ASE 95NP
Water (1/1 mole) 9.3 0.8 0.07 Carbon black 33 0.45 0.15 * ammonium stearate The above foamed latex mixture was coated onto the upper surface of a preformed glass fiber mat containing 27.5 wtA urea-formaldehyde binder and having 72.5 wt.%
of average 114 inch long filaments of 15.9 micron average diameter. Coating was accomplished using a Gardner draw-down gauge set to achieve a coating thickness of 30 mils on the mat. The resulting sample was dried in an oven at 125 C. for 3 minutes and then cured at 150 C. for an additional 3 minutes.
The properties of above facer sample was compared with those of commercial samples A, B and C. and the results were as recorded in Table 2.
Example 1 was repeated except that self-. ...
crosslinkable acrylic (RHOPLEX"" B-959) was substituted for latex (E-693) and the dried prefoamed mixture on the mat was not cured. The unfoamed mixture of this example had a Brookfield viscosity of 3,600 cps.
The uncured, foam-coated mat of this example was introduced to a laminator wherein the uncoated fiber under surface of the mat was contacted with a foamed polyurethane/isocyanurate core of an insulation board and the simultaneous curing of the mat foam and the core was initiated. After about 1-2 minutes in the laminator, at a temperature of about 120 to 200 C, the laminated board was cut into 4 x 8 foot boards and the boards squares stacked in units of 25 members to complete curing over a period of 2.5 days.
Example 1 was repeated except that an additional 45 g of aluminum trihydrate (ALCOA GRADE C-320) was added to the coating mixture to increase flame retardance of the facer. The Brookfield viscosity of the unfoamed mixture was 2,200 cps and the foam had a density of 0.23 g/cc.
Conventional facers most commonly employed are non-coated, cellulose fiber mats which may or may not be reinforced with a minor amount of glass fibers. In Table 2, Examples A and B represent this type. Example A is reinforced with 18% of 114 inch long glass fibers, Example B is reinforced with 13% of less than 1/8 inch long glass fibers.
Another type of facer which has had commercial success comprises a glass mat on which a polyethylene coating has been extruded. A facer of this type is represented as Sample C.
The properties of all of the facers in the above examples are reported in following Table 2.
~
~
.,~
O N ~'~1 m V r.{ (n m f~1 1 1 I I I I
[~ '-1 ~-1 t0 N1 1 I I I I I
(O~
U
ri ~0 .,~
V O OD ~O O O
~N (A N OD O N [~ ~1 ~O [~ ~ ~
~ N ~==1 01 d' r=1 r1 ~=-I N O~-i O
U
~
N
.,~
~ to CD ~c1 m IA .~-1 tOo ~ ,~', 01 OD O Orn m c~1 rn O
e-1 ~==1 a~ N.-1 N f~1 N1 O O
O
U
~+1 N O
r N [~ d N N N
~ ~ . .
H ~ If! tl1 Lf1 In O C~D f~ I O O
W .-1 f+~1 P'1 V~ c+l (*1 sT 1 O O
N
m /-~I
q ri t0 ~O '-1 N N
Id [~ aD I O O
k M 1f1 .-I d fn m rl I
W ri f~'1 d' rP f*1 C~1 t11 I O O
~-i m ~
~ ~ ~ ~~ O!` 00 M. n') t[1 r=1 ul s! 01 111 O
yr~ r 1 (+r1 d' d V f+) V~ t0 O O
1~
~ ~ ~~
w tn =~ o ,"~ w ~rl ~
~ `~ u ~ ~i .v o b~ 0 1~1 rn ~4 J=~ A
~i ~" ,ai ~ N ~ N r +1 ~ O
~ tn ~ .~-1 a~i ~ A W ~ (~ ~ ~ a~~+i ~j ~ 1 ~ ~ I .F ~ O C) A .ti (~ ~ .Oi 1~ ~i U
f~ ~o mA d ~~A Tl 0 O m a ' ~\ p' ~ A ai ~~ m o~ ~-oi ai w a c~~ c`~~~ aw H~~ w b+~ ~ A~=
The above examples are representative and it will. be understood that many alterations and substitutions can be made therein without departing from the scope of this invention.
Claims (24)
1. A flexible, low fiber containing facer suitable for use in building construction and containing less than 50 wt.% fiber, which comprises a non-asphaltic, non-cellulosic fiber mat substrate of between about 10 and about 30 mils thickness in contact with a 5 to 100 mil thick mat surface coating of between about 15 and about 80 wt% of a foamed mixture containing, on a dry weight basis, (a) between about 15 and about 80 wt.% of a thixotropic polymer latex, (b) a strengthening or fire retarding amount of between about 0.01 and about 80 wt.% of an inorganic filler and (c) a foam building, foam sustaining amount of between about 0.5 and about 10 wt.% of an organic surfactant.
2. The facer of claim 1, wherein the fiber of said mat is glass fiber.
3. The facer of claim 2, wherein said fibers have an average diameter between about 3 and about 20 microns and a length of between about 0.25 and about 1.75 inch.
4. The facer of any one of claims 1 to 3, wherein (c) is an ammonium salt of a Cl0 to C22 fatty acid.
5. The facer of claim 4, wherein (c) is ammonium stearate.
6. The facer of any one of claims 1 to 5, wherein said latex of (a) is an acrylic based resin.
7. The facer of any one of claims 1 to 6, wherein said foamed mixture additionally contains up to 15 wt% of an excipient selected from the group of a thickener, a coloring agent, a texturizing agent, a UV light stabilizer, a thermal stabilizer, a flame retardant, a weather resistance agent and a blowing agent.
8. The facer of claim 7, wherein the UV light stabilizer is present in an amount of up to about 2.5 wt.%
of the mixture.
of the mixture.
9. The facer of any one of claims 1 to 8, wherein the facer contains 30 to 46 wt.% of the fiber.
10. The facer of any one of claims 1 to 9, wherein said coating has a density of between about 0.1 and about 4 g/cc.
11. A process for preparing the facer of claim 1, which comprises:
(i) forming a 15 to 80 wt.% aqueous mixture of (a), (b) and c);
(ii) foaming the mixture from (i) to a self-sustaining consistency;
(iii) applying a 5 to 80 mil uniform coating of the foamed mixture from (ii) to one surface of said mat;
(iv) drying the resulting mat; and (v) recovering the dried, foam coated mat having a fiber concentration below 50 wt.% as a product of the process.
(i) forming a 15 to 80 wt.% aqueous mixture of (a), (b) and c);
(ii) foaming the mixture from (i) to a self-sustaining consistency;
(iii) applying a 5 to 80 mil uniform coating of the foamed mixture from (ii) to one surface of said mat;
(iv) drying the resulting mat; and (v) recovering the dried, foam coated mat having a fiber concentration below 50 wt.% as a product of the process.
12. The process of claim 11, wherein the foam coated facer is dried and cured and then passed to a laminator for lamination to a non-elastic insulation board core.
13. The process of claim 11, wherein the foam coated facer is dried at below its curing temperature and is then passed to a laminator where the dried foam is contacted with a non-elastic lamination board core and is cured thereon.
14. A siding underlayment having a conventional non-elastic core laminated to the facer of any one of claims 1 to 10.
15. An insulation board having a non-elastic core laminated on a surface to the facer of any one of claims 1 to 10.
16. The insulation board of claim 15, wherein the opposite surface of said core is laminated to a conventional cellulose- or asphaltic-containing mat.
17. An insulation board having a non-elastic core wherein both surfaces of said core are laminated to the facer of any one of claims 1 to 10.
18. The insulation board of any one of claims 15 to 17, wherein said inorganic filler is a fire retardant agent.
19. The insulation board of claim 18, wherein said inorganic filler is aluminum trihydrate.
20. The insulation board of any one of claims 15 to 19, wherein said mat contains less than 50 wt.% of the fiber.
21. The insulation board of claim 20, wherein said mat contains between about 30 and about 46 wt.% of the fiber.
22. The insulation board of any one of claims 15 to 21, wherein said facer is a glass mat surfaced with said cured foam.
23. The insulation board of any one of claims 15 to 22, having a thickness of between about 0.2 and about 4 inches.
24. The insulation board of any one of claims 15 to 23, wherein said coating has a density of between about 0.1 and about 0.4 g/cc.
Applications Claiming Priority (7)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US9945198P | 1998-09-08 | 1998-09-08 | |
US60/099,451 | 1998-09-08 | ||
US09/376,247 | 1999-08-18 | ||
US09/376,275 | 1999-08-18 | ||
US09/376,247 US6368991B1 (en) | 1998-09-08 | 1999-08-18 | Foamed facer and insulation boards made therefrom |
US09/376,275 US6365533B1 (en) | 1998-09-08 | 1999-08-18 | Foamed facer and insulation boards made therefrom cross-reference to related patent application |
PCT/US1999/019499 WO2000014358A2 (en) | 1998-09-08 | 1999-08-26 | Foamed facer and insulation boards made therefrom |
Publications (2)
Publication Number | Publication Date |
---|---|
CA2340451A1 CA2340451A1 (en) | 2000-03-16 |
CA2340451C true CA2340451C (en) | 2009-12-15 |
Family
ID=27378832
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA002340451A Expired - Lifetime CA2340451C (en) | 1998-09-08 | 1999-08-26 | Foamed facer and insulation boards made therefrom |
Country Status (9)
Country | Link |
---|---|
EP (1) | EP1115562B1 (en) |
JP (1) | JP2002524316A (en) |
AT (1) | ATE303245T1 (en) |
AU (1) | AU5786699A (en) |
CA (1) | CA2340451C (en) |
DE (1) | DE69927038T2 (en) |
DK (1) | DK1115562T3 (en) |
ES (1) | ES2249025T3 (en) |
WO (1) | WO2000014358A2 (en) |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6913816B2 (en) * | 2001-10-02 | 2005-07-05 | Building Materials Investment Corporation | Composite mat product for roofing construction |
US7429544B2 (en) | 2004-04-16 | 2008-09-30 | Owens Corning Intellectual Capital, Llc | Coated facer |
GB0606468D0 (en) * | 2006-03-31 | 2006-05-10 | Ici Plc | Improved paint compositions |
CA3123938A1 (en) * | 2018-12-19 | 2020-06-25 | Owens Corning Intellectual Capital, Llc | Thin layer uv curing coating on non-woven facers |
Family Cites Families (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CA1135127A (en) * | 1979-05-07 | 1982-11-09 | George R. Ferment | Process for sealing fiber web of open structure |
JP2593945B2 (en) * | 1988-07-25 | 1997-03-26 | インターフェイス,インコーポレイテッド | Latex glued pile carpet |
US5102728A (en) * | 1990-08-17 | 1992-04-07 | Atlas Roofing Corporation | Method and composition for coating mat and articles produced therewith |
US5001005A (en) * | 1990-08-17 | 1991-03-19 | Atlas Roofing Corporation | Structural laminates made with novel facing sheets |
JPH05286069A (en) * | 1992-04-15 | 1993-11-02 | Matsushita Electric Works Ltd | Phenol-resin molded form and manufacture thereof |
US5635248A (en) * | 1995-06-07 | 1997-06-03 | Rohm And Haas Company | Method of producing coating on reconstituted wood substrate |
US5717012A (en) * | 1995-11-03 | 1998-02-10 | Building Materials Corporation Of America | Sheet felt |
-
1999
- 1999-08-26 DK DK99945214T patent/DK1115562T3/en active
- 1999-08-26 JP JP2000569084A patent/JP2002524316A/en active Pending
- 1999-08-26 AU AU57866/99A patent/AU5786699A/en not_active Abandoned
- 1999-08-26 WO PCT/US1999/019499 patent/WO2000014358A2/en active IP Right Grant
- 1999-08-26 CA CA002340451A patent/CA2340451C/en not_active Expired - Lifetime
- 1999-08-26 ES ES99945214T patent/ES2249025T3/en not_active Expired - Lifetime
- 1999-08-26 EP EP99945214A patent/EP1115562B1/en not_active Expired - Lifetime
- 1999-08-26 AT AT99945214T patent/ATE303245T1/en not_active IP Right Cessation
- 1999-08-26 DE DE69927038T patent/DE69927038T2/en not_active Expired - Lifetime
Also Published As
Publication number | Publication date |
---|---|
AU5786699A (en) | 2000-03-27 |
EP1115562A2 (en) | 2001-07-18 |
DE69927038T2 (en) | 2006-06-08 |
DK1115562T3 (en) | 2006-01-02 |
EP1115562B1 (en) | 2005-08-31 |
WO2000014358A3 (en) | 2000-06-08 |
WO2000014358A2 (en) | 2000-03-16 |
JP2002524316A (en) | 2002-08-06 |
EP1115562A4 (en) | 2001-11-21 |
DE69927038D1 (en) | 2005-10-06 |
ATE303245T1 (en) | 2005-09-15 |
CA2340451A1 (en) | 2000-03-16 |
ES2249025T3 (en) | 2006-03-16 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US6365533B1 (en) | Foamed facer and insulation boards made therefrom cross-reference to related patent application | |
US6774071B2 (en) | Foamed facer and insulation boards made therefrom | |
US6368991B1 (en) | Foamed facer and insulation boards made therefrom | |
US6996947B2 (en) | Building product using an insulation board | |
US5112678A (en) | Method and composition for coating mat and articles produced therewith | |
US5102728A (en) | Method and composition for coating mat and articles produced therewith | |
US6044604A (en) | Composite roofing members having improved dimensional stability and related methods | |
CA2216027C (en) | Composite roofing members having improved dimensional stability and related methods | |
US7749598B2 (en) | Facer and faced polymeric roofing board | |
CA3096340C (en) | Roof cover board derived from engineered recycled content | |
US10450741B2 (en) | Construction boards with coated inorganic facer | |
US8268737B1 (en) | Facer and construction materials made therewith | |
CA1251905A (en) | Sheet type felt | |
CA2649808A1 (en) | Structural insulation sheathing | |
US6913816B2 (en) | Composite mat product for roofing construction | |
CA2340451C (en) | Foamed facer and insulation boards made therefrom | |
US20110171456A1 (en) | Insulation material providing structural integrity and building elements and composites made thereof | |
CA2774509C (en) | Facer and construction materials made therewith | |
US3211597A (en) | Method of roof construction | |
MXPA01002235A (en) | Foamed facer and insulation boards made therefrom | |
KR200330933Y1 (en) | panel for inner finishing materials | |
US12115768B2 (en) | Prepregs, cores, composites and articles including repellent materials | |
JPS63896Y2 (en) | ||
JPH01301236A (en) | Improved phenol resin foamed material | |
JPS60174642A (en) | Laminated heat-insulating material made of synthetic resin |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
EEER | Examination request | ||
MKEX | Expiry |
Effective date: 20190826 |