DE69927038T2 - DUMPED COATING AND INSULATION PLATES MADE THEREwith - Google Patents

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

BACKGROUND THE INVENTION

In The construction industry has been finding insulation laminates made of rigid foam for many years Polymer base application. These are used in commercially available insulation boards for roofs under Asphalt composite roof membranes (BUR membranes) as well as under different single layer membranes, e.g. EPDM rubber, PVC, modified Bitumen membranes and the like may be used. These will also for insulation in residential buildings, as coatings for exterior coverings and as a roof insulation used under asphalt shingles and concrete roof tiles.

A such insulation is common in the form of a foamed thermosetting polymeric core material, such as e.g. Polyurethane, polyisocyanurate, Polyurethane-modified Polyisocyanurate (often referred to as polyiso) or phenolic resin, the is applied between two cladding panels.

These insulation boards are generally manufactured in production lines where a liquid core chemical mixture over a Cast bottom cover, the mixture is foamed, around a top cover in a laminator with restricted outlet to contact. The reaction of the chemical mixture causing foaming is generally exothermic, since curing by means of polymerization and crosslinking takes place in the laminating machine. In the case of insulation boards from polyisocyanurate takes the curing exotherm until the resulting hardboard is cut to size, stacked and stored. The exotherm can take up to 4 days and the mixture reaches a high temperature of 163 ° C (325 ° F).

preferred Properties for the covers include flexibility, high tensile and tear strength and Thermal decomposition resistance. The covers should be over low porosity feature, and their coating thickness should be sufficient to pass through the liquid Chemicals before foaming to prevent. In addition, the covers should be good adhesion to the Core foam insulation exhibit and opposite Effects of other chemicals that may be present in the mixture, inert be, in particular propellants, which also act as a solvent. Currently used Propellants include chlorofluorocarbons, e.g. HCFC-141b and R-22, and hydrocarbons, e.g. n-pentane, cyclopentane and isopentane.

One The problem facing the polyiso industry is the phenomenon of "delamination at cold temperatures ". This phenomenon occurs in cold-temperature areas where they come out of the production line insulation boards cooling down, before they can be "stack hardened". in the unfavorable Case cools the closest to the cover lying Polyisokernschaumschicht, which quenching the curing reaction leads and a fragile one Layer leaves behind. Thereby it happens often for shearing the core layer or peeling off the cover. Manufacturer usually place a layer of corrugated cardboard over both the top surface the cover of the top plate as well as under the bottom surface of the Cover the bottom plate on the stack to keep the exothermic To maintain heat and a subsequent one Prevent delamination. Consequently, a cover that inherently insulates and would the heat while of pile hardening maintains, the frequency materially reduce delamination during cold weather and obviate the need for costly insulating cartons.

After this this foamed polymeric insulation boards hardened, tailored and shipped to the respective site are, the cover should be over mechanical stability as well as water and weather resistance this maybe after the installation Constant rain, high humidity, UV light and extreme heat exposed is. In addition, must the covers are puncture resistant and resistant to abrasion to survive nails and walking on it. Withstands temperatures up to 260 ° C (500 ° F), such as in hot asphalt applications and resistance to deleterious effects of adhesive solvents, which are used in single-layer roof membrane applications, while they bind firmly to the adhesives themselves are also important Properties of covers.

Conventionally, cover materials include cellulosic integrated asphalt-saturated building boards, fiberglass mats, asphalt emulsion coated fiberglass mats, aluminum foil / kraft / foil, cellulosic fiberglass modified building boards, glass mats on which polymer films have been extruded, and glass mats coated with polymer latex and inorganic binder coatings are coated on. However, all of these materials have at least one undesirable property. at For example, asphalt-containing products are not compatible with PVC single-layer roofing membranes. Fiberglass mats are subject to heavy penetration of the foamable core chemicals. Aluminum covers and foils reflect heat into the foam during processing, resulting in disruption of cell structure, delamination and warping. In addition, film-covered coating and extrusion or lamination of a polymer film onto glass mat surfaces is costly. In particular, glass mats coated with mixtures of polymer latex or inorganic binders have proved to be brittle; in contrast, cellulosic fiberglass-modified construction boards are susceptible to moisture absorption, which enhances sheet warping in humid or wet environments.

Other Covers to the exterior paneling of lower layers and for insulation of panel covers include those in U.S. Patent Nos. 5,776,841 and 5,717,012, which are mainly construction boxes.

In US Pat. No. 5,001,005 describes a cover plate, which consists of glass fibers and a binder that is not asphalt is. The cover has 60 to 90% glass fibers, wherein the high fiber content does not provide enough binder to the plate pores close or a desired one Provide plate strength. In U.S. Patent No. 5,102,728, in which a glass mat substrate is described, with a latex on Polymer base is coated, which mixed in an asphalt emulsion is, a product is treated that not only with the roofing membranes made of PVC incompatible is, but also an excessive coating thickness requires the high porosity to reduce. Consequently, this product is very expensive. In US Pat. No. 5,112,678, a cover disclosed by US Pat Applying a flowable polymer latex and an inorganic binder coating on a fiberglass mat will be produced. The resulting product is a bit brittle and for one undesirable Degree of chemical penetration prone. In U.S. Patent Nos. 5,698,302 and 5,698,304 covers are described in which Polymer films are laminated or extruded onto Fibreglas mats. This method is not only costly, it also that conventional flame retardant Polymers with mineral filler are difficult to extrude, a certain degree of resistance to the Flammability lost.

consequently It is an object of the present invention to overcome the above disadvantages and defects to fix and provide a cover by means of a commercially feasible Process is produced economically.

It is also an object of the invention, a mechanically stable cover to provide, which is suitable for the production of insulation boards and a Delamination in cold temperatures withstands as well as an excellent Tolerance Weathering has.

One Another goal is to provide a cover that has excellent Adhesion to polyiso foams an insulation board core material features.

These and other objects and advantages of the invention will be apparent from the following Description and Revelation evident.

SUMMARY THE INVENTION

The asphalt and cellulose-free cover of the present invention comprises a dry preformed fibrous mat substrate followed by a voraufgeschäumte or prefoamed Composition is coated, which is a natural or synthetic thioxotopes latex polymer, a surfactant and an inorganic mineral filler includes: The composition may optionally contain up to about 15% by weight of other additives contain the flame retardants, Dyes, thickeners, porosity reducing agents, heat and / or UV stabilizers and the like to provide a foamed cover product, based on the dry weight, less than 50% by weight of fibers contains in the mat. The preferred cover product contains from 30% to 46% by weight of fibers in the composition consisting of matted fibers with a binder and Latex exists in the coating mixture.

DETAILED DESCRIPTION OF THE INVENTION

in the General contains the foamed coating composition applied to a preformed mat, based on the dry weight, between 15 and 80 wt .-% of a thioxotropic polymer latex, between 0.01 and 80% by weight of a filler, between 0.5 and 10% by weight of a foam supporting surfactant and 0 to 15 % By weight of other additives.

The Matt fibers used in the present invention include all cellulose-free types, e.g. Glass fibers, polyester, Polypropylene, polyester-polyethylene-teraphthalate copolymers, Hybrid types, e.g. Polyethylene fiberglass, and other conventional ones cellulose-free fibers. Mats with randomly arranged glass fibers be due to their consistency across from Heat that during the production of insulation boards is produced, and the flame resistance preferred in the final product.

The fiber mats of the present invention, which are generally between 254 and 762 x 10 ^-3 mm (10 and 30 mils) thick, conventionally contain a binder which is incorporated during mat formation to fix the fibers in a self-sustaining solid wall, and the like To prevent loss of fibers during subsequent processing and handling. Such binders include phenolic, melamine and / or urea-formaldehyde resins or mixtures thereof. In particular, those mats are preferred which have glass fibers having a diameter in a range of 3 to 20 microns, more preferably 10 to 18 microns, and a length of 0.64 to 4.45 cm (0.25 to 1.75 inches) in length. , in particular 1.91 to 3.81 cm (0.75 to 1.5 inches).

The for the present coating mixture suitable fillers include conventional inorganic types, e.g. Clay, mica, talc, limestone, kaolin, other rock dust, gypsum, aluminum silicate (for example Ecca Tex 561), flame retardant Aluminum trihydrate, ammonium sulfamate, antimony oxide, calcium silicate, Calcium sulfate and mixtures thereof.

The surfactants used in the coating composition are of the organic type useful for stabilizing latexes, such as ammonium salts of a C ₁₀ -C ₂₂ fatty acid, eg, ammonium stearate (STANFAX 320). One or more surfactants may be used in the coating composition to accelerate foaming and to maintain the foam structure of the coating prior to curing.

The Latex component of the coating composition includes latex polymers of natural rubber and synthetic latexes, including copolymers of styrene and butadiene and acrylic-based resins. Representative examples are polyvinyl chloride, Styrene / acrylic acid or methacrylic acid ester, ethylene / vinyl chloride and polyurethane, polyisoprene, polyvinylidene chloride, polyvinyl acetate / polyvinyl chloride and synthetic rubbers, e.g. SBS, SBR, neoprene etc., as well any thioxotropic polymer latex and mixtures of the foregoing Examples.

The mat coating mixture according to the invention is obtained from a foamed aqueous emulsion, dispersion or suspension with 15 to 80 wt .-%, which is prefoamed by the introduction of air into the aqueous liquid mixture, for example by blowing or mixing, in the presence or absence of a conventional propellant. The resulting frothed or foamed, aerated composition is then coated on the preformed mat surface under ambient conditions using a knife blade, a roller or any other conventional application method to a thickness from 127 to 2540 x 10 ^-3 mm (5 to 100 mils). In one aspect, the foam-coated mat is then dried below its cure temperature to yield a foamed, self-sustaining product having a reduced coating thickness of up to 2286x10 ^-3 mm (90 mils) and adhered to the mat surface. In another aspect, the foam-coated mat is dried and cured simultaneously.

The resulting cover product of the present invention is preferred flexible and has a low permeability to liquid chemicals that for insulating cores be used, and has an outstanding dimensional stability and high tensile strength after curing. This product, the mat with an adhesive surface coating from prefoamed Latex / filler / surfactant may include, in the insulation board manufacturing fed directly For example, for a limited-outlet laminator, wherein the uncoated fiber surface of the mat is at least one exposed surface a foamed or foamable thermosetting non-elastomeric core in the manufacture of one as follows described insulation board contacted.

As noted above, the foamed coating of the present cover can be formed in the presence or absence of a blowing agent to provide a composition of reduced density, the density of which is above 2 g / cm ³ (g / cc) to a low 0.15 g / cm ³ (g / cc) can be reduced. Advantageously, the foam is such that the coating mixture does not penetrate through the mat and ideally resembles the consistency of shaving cream.

In general, the amount of air that enters the foamable mixture before coating for optimal texture, about 5 to about 80 volume percent, and the resulting foamed mixture has bubble openings small enough to inhibit the passage of liquids through the mat.

The Applying a film or laminating a layer of impermeable resin or polymer on the foamed surface for providing a cover member having three layers in special cases, in which this is desired is, a complete one liquid impermeable surface provide the cover. For For this purpose, a top coat of a non-foamed latex is suitable. Alternatively, a thermoplastic such as e.g. polyethylene powder or not foamed Polystyrene beads, as a filler used, which melts at the drying or curing temperatures, to close substantially all pores of the permeable coating. Foamable auxiliaries and additives, e.g. Cellulose can also be used for this Purpose to be used, with the use of a sealing coat neither required nor recommended. Other procedures that have a similar To serve a purpose, include the use of less air during foaming, the Omitting or using less inorganic fillers in the coating composition, calendering and / or pressing the foamed or foamed surface by means of contact with a hot roller or a press table. Another method for producing a completely impermeable surface comprises forming the foam on the smooth surface of a conventional one Separating material and the subsequent Contacting the mat with the opposite surface of the Foam. If necessary, a combination of all the above options for specific Purposes are applied.

in the present case the cover of the invention with a foamed cellular Coating a latent exothermic energy and shows on entry in the laminator a higher potential heat capacity on which the lamination cure time and the heat generation is prolonged by using this as insulation while of hardening in the pile after hardening acts. Due to this advantage, the requirement for heat preserving Elements on the upper and Bottom of the stack eliminated and the previous problem regarding the susceptibility the plate is reduced to delamination at cold temperatures. In addition, in places where the foam coating on the cover dried and / or cured is the bond strength between the uncoated fibers and the core material in the resulting product due to the reduced Passing the coating mixture into the mat because of its prefoamed state improved. In areas where the foam of the cover before entering in the laminator completely hardened is the core material either on the uncoated fibrous surface of the Cover poured or by means of adhesives or binding agents laminated on it.

Everyone any pressure during lamination in the manufacture of insulation boards can, is less than the pressure required to achieve a 50% reduction in thickness the foamed Cover coating effect, and is not sufficient to damage or a crush the mat fibers in Enddämmplattenprodukt respectively.

The weight of the present cover may vary from 40 to 300 g / m ² , and the foamed cover plate may have a thickness of up to 2,540 x 10 ³ mm (100 mils), depending on the consumer's preference. For certain purposes requiring more consistent coverage, latexes can be selected that can be crosslinked.

The present latex coating composition may also have a low Amount of up to 15% by weight, preferably less than about 3% by weight, a conventional one Thickener, for example, an acrylic polymer thickener such as. (ACRYSOL ASE 95NP and / or 60 NP) and the like. Other inert adjuvants, such as e.g. UV or thermal stabilizers, a conventional Dye, a texturizing agent, enhancer or crosslinker (e.g. Resin CYMEL 303) and / or blowing agents may also be used in the coating mixture be included, with the addition of these additives in a small amount Amount of less than 2 wt .-% is preferred.

The insulation boards, for which the present cover is particularly suitable, includes conventional thermosetting or thermoplastic foam cores, e.g. foamed polyurethane or polyurethane modified Polyisocyanurate or phenol-formaldehyde cores, which are between a pair of cover elements laminated to the core surfaces are. Other non-elastomeric foamable Chemicals, e.g. Polyvinyl chloride, polystyrene, polyethylene, Polypropylene and other conventional used as nuclear material also as Dämmplattenkerne of the present invention. Hard, foamed cores of this type are described, for example, in US Patent 4,351,873.

The Covers present are also suitable for coating an outer lining sublayer, which generally has a thickness of up to about 2.54 cm (1 inch) and a non-elastic core material of a chemical or a chemical mixture similar to that of a Dämmkerns. The use of locally formed covers makes the need superfluous of costly foil covers that hold and reflect heat and often lead to deformations and deterioration of the wood topcoat. As well be slides and the like Covers slightly perforated, causing moisture leads.

at the production of the insulation becomes a role of the present foamed cover sheet product with its uncoated fiber surface opposite the core surface given a laminating zone. The foamed slab core foam precursor chemical or a chemical mixture can be applied to the uncoated fiber surface of the Cover plate of the insulation board be poured, or the core of the insulation board can become a self-sustaining Texture prefoamed become. In one embodiment is a first cover according to the invention, with its uncoated surface abutting at the core, below of the core. The fiber surface of the second cover becomes positioned and arranged above the core to allow core foaming, e.g. in a laminator with restricted outlet, where the arrangement undergoes an exothermic reaction and hardening is initiated. While of hardening the core material is foamed and rising to the bottom uncoated surface of the second cover to come into contact. It is understood that one the first and second covers the same or a different one Compound tion than those of the present invention may be, wherein it is preferred that both covers be those of those described herein present invention. In particular, one of the cover plates from those conventional applied selected be such as a cellulose or cellulose-glass hybrid construction board, Perlite, aluminum foil, multiple sheets of foil and kraft, uncoated or coated fiberglass mats, wherein the second cover plate according to the invention enhances the benefits described herein. When the core foam on the fibrous surface the first cover plate entering the laminating machine is distributed, passes through this one exothermic reaction, which has a temperature of up to about 93 ° C (200 ° F) can reach. The core foam rises to the bottom surface of the contact the second cover and harden it, causing a hard insulating foam core is provided between the two cover plates interposed or is trapped. The resulting product can subsequently be dissolved in Plates with desired Size and shape be tailored. The exothermic heat of reaction, the polymerization and / or Networking arises, both in the laminating machine as well as in the subsequent stacking of the insulation boards by itself, to one full hardening of the core and the surface coating to ensure the coverage. The curing temperatures while of stacking increase up to about 163 ° C (325 ° F) over a period of up to 4 days.

When further embodiment, The above course may include the top and bottom positioning the cover plates are turned over so that the cover according to the invention in such a way over a conventional one Cover supplied and above is applied that their non-coated fibrous surface of the expandable insulating core confronts and on its lower surface contacted with another cover plate. The latter Method is used when a cover is a rigid plate is, as this, in contrast to a flexible according to the invention Cover supplied to the laminating machine as a continuous roll can, with a perlite or a particle plate cover the Case is. In this case, the foamable insulating core chemical will stiffen onto the surface of the Cover element applied and rises to the fibrous uncoated Surface of the This cover come into contact.

Of the Latex of the cover surface layer according to the invention can the heat between the layers of the roll due to its comparatively thick latex foam and low fiber coating latex ratio maintained more efficiently. Thus, the lamination of the core at faster speed and stacking done without damage of the laminate. In addition, it has now been found that the heat retention while of hardening improves the core bond and the subsequent "delamination at cold temperatures" of the product significantly reduced, which is caused by the fact that the upper class of the insulation due to exposure to cooler temperatures during the Stacking after exiting the laminator is not fully cured.

The insulation boards, the covers of the invention are suitable for industrial roof insulation, for wall coverings in residential buildings or Industrial buildings etc. Depending on the purpose, the present insulation board a core thickness that can vary widely, for example between 1.27 and 10.2 cm (0.5 to 4 inches) or more.

Out the above discussion shows that it is also possible the insulating core to form separately, i. in the absence of contact between the Fibers of a cover, and subsequently one or more of the present Covers to the core using suitable adhesives to bind. In general, the teachings of US Patent 5,351,873 on the formation of the stiff foam cores and the adhesion of the cover plates to at least one surface such cores applicable.

When Core materials are the most common Polyurethane and polyisocyanurate, other nonelastomers, expandable Chemicals are also used. Examples of the latter include polyvinyl chloride, Polystyrene, phenolic resins and the like.

The Covers and the insulation board products of the present invention have a significantly higher tensile strength as those containing 60 to 90% by weight of fibers. The present Covers have also over a crack resistance at low temperatures and outstanding dimensional stability and flame retardation. Because of their superior Strength and flexibility can the present covers broader applications find, such as non-film, anti-glare coatings, such as Brick underlayers Separation or barrier layers and the like.

EXAMPLE 1

• * Ammoniumstearat

A 473 ml capacity metal can with a low shear mixer was used to add a 51.5% aqueous solution of a self-crosslinkable acrylic latex (Rohm & Haas, E-693), a 23.5% aqueous clay slurry (Ecca Tex 561) Mixture of a melamine crosslinker (CYMEL 303), an ammonium stearate foam stabilizer (STANFAX 320), an acrylic polymer thickener (Acrysol ASE 95NP) and a carbon black pigment in the amounts listed in Table 1 below. The above ingredients were mixed for about 10 minutes good and subsequently foamed using a high speed Kitchen Aid mixer to produce a foam having a density of 0.2 g / cm ³ (g / cc). The Brookfield viscosity of the foamed mixture was 1,500 cP using a No. 4 LVT spindle at 30 rpm. TABLE 1

• * Ammonium stearate

The above foamed latex blend was coated onto the top surface of a preformed fiberglass mat containing 27.5 weight percent urea-formaldehyde binder and having 72.5 weight percent filaments on average 3.18 cm (1 1/4 inch) long mean diameter was 15.9 microns. Coating was performed using a Gardner vacuum ^draw gauge to achieve a coating thickness of 762 x 10 ^-3 mm (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 a further 3 minutes.

The Properties of the above cover sample were compared with the commercial ones Samples A, B and C are compared and the results are in Table 2 quoted.

EXAMPLE 2

The Example 1 was repeated except that instead of the latex (E-693) a self-crosslinkable acrylic (RHOPLEX B-959) was used and the dried prefoamed Mixture on the mat not hardened has been. The unfoamed Mixture of this example had a Brookfield viscosity of 3600 cP on.

The uncured, Foam-coated mat of this example was placed in a laminator introduced, wherein the uncoated fiber is below the surface of the mat with a foamed polyurethane isocyanurate core an insulation board kon was clocked and the simultaneous hardening of the matting foam and the core was initiated. After about 1 to 2 minutes in the laminator at a temperature of about 120 to 200 ° C was the laminated plate to 122 × 244 cm (4 × 8 Foot) big plates tailored and the plate squares in units of 25 elements stacked to hardening in a period of 2.5 days to complete.

EXAMPLE 3

Example 1 was repeated except that an additional 45 grams of aluminum trihydrate (ALCOA grade C-320) was added to the coating mix to increase the flame retardance of the cover. The unfoamed mixture of this example had a Brookfield viscosity of 2,200 cps and the foam density was 0.23 g / cm ³ (g / cc).

The most frequently used conventional Covers are uncoated cellulose fiber mats that are coated with a small amount of glass fibers reinforced or not reinforced can. In Table 2, Examples A and B represent this type. Example A is reinforced with 18% 3.2 cm (1 1/4 inch) long glass fibers, example B is reinforced with 13% less than 0.32 cm (1/8 inch) long glass fibers.

One another type of cover, which was granted commercial success, comprises a glass mat on which a polyethylene coating is extruded has been. A cover of this type is shown as sample C.

The Features of all covers. The above examples are shown below Table 2.

The The above examples are illustrative and it is understood that that many changes and Replacements of these embodiments possible are, without departing from the scope of the invention departing. The definition of the invention is to the appended claims remove.

Claims (28)

Flexible low fiber cover suitable for use in building construction containing, by dry weight, less than 50% by weight of fibers comprising a asphalt-free, cellulose-free fibrous mat substrate having a thickness between 254 and 762 x 10 ^-3 mm (10th to 10th) and 30 mils), wherein the mat substrate is in contact with a 127 to 2540 x 10 ^-3 mm (5 to 100 mils) thick mat surface coating, the coating being obtained from a foamed 15-80 wt% aqueous mixture based on the Dry weight, (a) between 15 and 80% by weight of a thixotropic polymer latex, (b) between 0.01 and 80% by weight of an inorganic filler and (c) between 0.5 and 10% by weight of an organic surfactant contains. A cover according to claim 1, wherein the fibers of the mat Are glass fibers. A cover according to claim 2, wherein the fibers comprise a average diameter between about 3 and about 20 microns and a length of between 0.64 and 4.5 cm (0.25 and 1.75 inches). Cover according to claim 1, wherein (c) an ammonium salt of a C ₁₀ - to C ₂₂ fatty acid. A cover according to claim 6 wherein (c) is ammonium stearate is. A cover according to claim 1, wherein the latex of the coating mixture an acrylic-based resin. A cover according to claim 1, wherein the coating mixture Furthermore up to 15% by weight of an adjuvant which is from the one Thickener, a dye, a texturizer, a UV light stabilizer, a heat stabilizer, a flame retardant, a weathering resistance agent and a blowing agent group is selected. A cover according to claim 7, wherein a UV stabilizer in an amount of up to 2.5% by weight of the mixture. A cover according to claim 1, wherein the cover 30 contains up to 46 wt .-% fibers. The cover of claim 1, wherein the coating has a density of between about 0.1 and about 4 g / cm ³ . A method of making a cover according to claim 1, comprising: (a) forming a 15-80 weight percent aqueous mixture of the coating composition, (b) foaming the mixture to a self-sustaining consistency, (c) applying a 127 to 2032 x 10 ^-3 mm (5 to 80 mils) thick uniform coating of the foamed mixture onto a surface of the mat, (d) drying the resulting mat, and (e) obtaining the dried foam-coated mat having a fiber concentration below 50% by weight. as a product of the process. The method of claim 11, wherein the foam coated Cover dried and hardened and then put in a laminator to attach to a non-elastic insulation board core to laminate. The method of claim 11, wherein the foam coated Cover dried at a temperature below its cure temperature and then put in a laminator where the dried foam contacted with a non-elastic laminated core and hardened on it becomes. Siding pad with a conventional one non-elastic core laminated to a cover according to claim 1 is. Insulation Board with a non-elastic core that has a surface on an asphalt-free, cellulose-free mat with low fiber content laminated according to claim 1. An insulating board according to claim 15, wherein the surfactant is an ammonium salt of a C ₁₀ to C ₂₂ fatty acid. Insulation Board according to claim 16, wherein the salt is ammonium stearate. Insulation Board A non-elastic core according to claim 15, wherein both surfaces of the Kerns are laminated to a cover according to claim 1. Insulation Board according to claim 15, having a non-elastic core, wherein a surface of the Kerns is laminated to a cover according to claim 1. Insulation Board according to claim 19, wherein the opposite surface of the Kerns on a conventional cellulose or asphaltene-containing Mat is laminated. Insulation Board according to claim 15, wherein the latex of the latex is an acrylic-based resin is. Insulation Board according to claim 15, wherein the filler is a flame retardant. Insulation Board according to claim 22, wherein the filler Aluminum trihydrate is. Insulation Board according to claim 15, wherein the mat contains less than 50% by weight of fibers. Insulation Board according to claim 24, wherein the mat comprises between 30 and 46% by weight of fibers contains. Insulation Board according to claim 15, wherein the cover plate is a glass mat, the with the hardened foam is coated. Insulation Board according to claim 15, having a thickness between 0.5 and 10.2 cm (0.2 and 4 inches). An insulating board according to claim 15, wherein the cured foam has a density between 0.1 and 0.4 g / cm ³ .