EP1115562B1 - Bardage en mousse et panneaux isolants qu'il permet de fabriquer - Google Patents

Bardage en mousse et panneaux isolants qu'il permet de fabriquer Download PDF

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Publication number
EP1115562B1
EP1115562B1 EP99945214A EP99945214A EP1115562B1 EP 1115562 B1 EP1115562 B1 EP 1115562B1 EP 99945214 A EP99945214 A EP 99945214A EP 99945214 A EP99945214 A EP 99945214A EP 1115562 B1 EP1115562 B1 EP 1115562B1
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EP
European Patent Office
Prior art keywords
facer
insulation board
mat
core
fiber
Prior art date
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Expired - Lifetime
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EP99945214A
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German (de)
English (en)
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EP1115562A2 (fr
EP1115562A4 (fr
Inventor
Charles J. Horner, Jr.
Frank S. Franzyshen
Murray S. Sherman
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Building Materials Investment Corp
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Building Materials Investment Corp
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Publication date
Priority claimed from US09/376,247 external-priority patent/US6368991B1/en
Priority claimed from US09/376,275 external-priority patent/US6365533B1/en
Application filed by Building Materials Investment Corp filed Critical Building Materials Investment Corp
Publication of EP1115562A2 publication Critical patent/EP1115562A2/fr
Publication of EP1115562A4 publication Critical patent/EP1115562A4/fr
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Publication of EP1115562B1 publication Critical patent/EP1115562B1/fr
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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

Definitions

  • 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.
  • BUR asphaltic built-up roof
  • 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.
  • a core polymeric foamed thermoset material such as polyurethane, polyisocyanurate, polyurethane modified polyisocyanurate (often referred to as polyiso) or phenolic resin
  • 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 exothermic, as curing via polymerization and crosslinking occurs in the laminator.
  • 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 163°C (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.
  • 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 260°C (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.
  • 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.
  • 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.
  • 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.
  • 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. 5,112,678 discloses a facer prepared by applying to a fiberglass mat a flowable polymer latex and an inorganic binder coating.
  • Another object is to provide 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 UV 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.% of fiber in the composition consisting of mat fiber with binder and latex in the coating mixture.
  • the foamed coating composition applied to the preformed mat contains on a dry weight basis between 15 and 80 wt.% of the thixotropic polymer latex, between 0.01 and 80 wt.% filler, between 0.5 and 10 wt.% foam supporting surfactant and 0 to 15 wt.% 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 254 and 762 x 10 -3 mm (10 and 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.
  • binders include phenol-, melamine- and/or urea- formaldehyde resins or mixtures thereof.
  • 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 561), flame retardant aluminum trihydrate, ammonium sulfamate, antimony oxide, calcium silicate, calcium sulfate, and mixtures thereof.
  • inorganic types such as clays, mica, talc, limestone, kaolin, other stone dusts, gypsum, aluminum silicate (e.g. Ecca Tex 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 C 10 to C 22 fatty acid, e.g. ammonium stearate (STANFAX 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.
  • 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 methacrylic 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 127 to 2540 x 10 -3 mm (5 to 100 mils) on the preformed mat surface under ambient conditions using a knife blade, a roller or any other convenient method of application.
  • 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 2286 x 10 -3 mm (90 mils) which adheres to the mat surface.
  • 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 hereinafter.
  • 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/cm 3 (g/cc) to as little as 0.15 g/cm 3 (g/cc).
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • the core material is cither 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 40 to 300 g/sq. meter and the foamed facer sheet can have a thickness up to 2540 x 10 -3 mm (100 mils) depending on the preference of the consumer.
  • 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 ASE 95NP and/or 60NP) and the like.
  • a conventional thickening agent for example an acrylic polymer thickener, e.g. (ACRYSOL ASE 95NP and/or 60NP) and the like.
  • Other inert excipients such as a UV or thermal stabilizer, a conventional coloring agent, texturizing agent, reinforcing or crosslinking agent, (e.g. CYMEL 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.
  • 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 2.54 cm (1 inch) and composed of a non-elastic core material of a chemical or chemical mixture similar to that of the insulation core.
  • a siding underlayment generally of a thickness up to about 2.54 cm (1 inch) and composed of a non-elastic core material of a chemical or chemical mixture similar to that of the insulation core.
  • 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.
  • 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.
  • 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.
  • 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.
  • the core foam 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 93°C (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 163°C (325°F) over a period of up to 4 days.
  • 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.
  • 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.
  • the present insulation board has a core thickness which may vary widely, for example between 1.27 and 10.2 cm (0.5 and 4 inches) or more.
  • 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 facers 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% aqueous clay slurry (Ecca Tex 561), a mixture of a melamine crosslinking agent (CYMEL 303), an ammonium stearate foam stabilizer (STANFAX 320), an acrylic polymer thickening agent (Acrysol ASE 95NP) and carbon black pigment in amounts shown in following Table 1.
  • the above foamed latex mixture was coated onto the upper surface of a preformed glass fiber mat containing 27.5 wt.% urea-formaldehyde binder and having 72.5 wt.% of average 3.18 cm (11 ⁇ 4 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 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 an additional 3 minutes.
  • 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 122 x 244 cm (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) g/cm 3 .
  • Example A is reinforced with 18% of 3.2 cm (11 ⁇ 4 inch) long glass fibers
  • Example B is reinforced with 13% of less than 0.32 cm (1/8 inch) long glass fibers.
  • a facer of this type is represented as Sample C.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Architecture (AREA)
  • Textile Engineering (AREA)
  • Acoustics & Sound (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
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  • Laminated Bodies (AREA)
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  • Machines For Manufacturing Corrugated Board In Mechanical Paper-Making Processes (AREA)
  • Chemical And Physical Treatments For Wood And The Like (AREA)
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Claims (28)

  1. Un barbage souple contenant une faible proportion de fibres, approprié pour être utilisé dans la construction immobilière et contenant, sur une base de poids sec, moins de 50% en poids de fibres, lequel comprend un substrat de matelas de fibres non-asphaltiques et non-cellulosiques d'entre 254 et 762 x 10-3 mm (10 et 30 mils) d'épaisseur, lequel substrat de matelas est en contact avec un revêtement de surface de matelas épais (5 à 100 mils) 127 à 2540 x 10-3 mm, ledit revêtement étant obtenu à partir d'un mélange aqueux en mousse de 15 à 80% en poids contenant, sur une base de poids sec, (a) entre 15 et 80% en poids d'un latex de polymère thixotrope, (b) entre 0,01 et 80% en poids d'une charge minérale et (c) entre 0,5 et 10% en poids d'un tensioactif organique.
  2. Le bardage de la revendication 1 dans lequel la fibre dudit matelas est de la fibre de verre.
  3. Le bardage de la revendication 2 dans lequel lesdites fibres ont un diamètre moyen entre environ 3 et environ 20 microns et une longueur d'entre 0,64 et 4,5 cm (0,25 et 1,75 pouces).
  4. Le bardage de la revendication 1 dans lequel (c) est un sel d'ammonium d'un acide gras en C10 à C22.
  5. Le bardage de la revendication 6 dans lequel (c) est du stéarate d'ammonium.
  6. Le bardage de la revendication 1 dans lequel ledit latex du mélange de revêtement est une résine à base acrylique.
  7. Le bardage de la revendication 1 dans lequel ledit mélange de revêtement contient en outre jusqu'à 15% en poids d'un excipient sélectionné dans le groupe d'un épaississeur, d'un agent colorant, d'un agent de texturation, d'un stabilisant contre l'effet de la lumière ultraviolette, d'un stabilisant thermique, d'un ignifuge, d'un agent de résistance aux intempéries et d'un agent de moussage.
  8. Le bardage de la revendication 7 dans lequel le stabilisant contre l'effet des ultraviolets est présent dans une quantité allant jusqu'à 2,5% en poids du mélange.
  9. Le bardage de la revendication 1 dans lequel le bardage contient 30 à 46% en poids de fibres.
  10. Le bardage de la revendication 1 dans lequel ledit revêtement a une densité d'entre environ 0,1 et environ 4 g/cm3 (g./cc).
  11. Le procédé de fabrication du bardage de la revendication 1 qui comprend les étapes consistant à:
    (a) former un mélange aqueux de 15 à 80% en poids de ladite composition de revêtement,
    (b) faire mousser ledit mélange à une consistance auto-sustentatrice,
    (c) appliquer un revêtement uniforme de 127 à 2032 x 10-3 mm (5 à 80 mils) du mélange en mousse sur une surface dudit matelas,
    (d) sécher le matelas résultant et
    (e) récupérer le matelas séché, revêtu de mousse et présentant une concentration en fibres en dessous de 50% en poids, comme étant le produit du procédé.
  12. Le procédé de la revendication 11 dans lequel le bardage revêtu de mousse est séché et amené à polymériser et est amené ensuite à passer vers une machine à stratifier en vue d'une stratification sur un noyau de panneau isolant non élastique.
  13. Le procédé de la revendication 11 dans lequel le bardage revêtu de mousse est séché à en dessous de sa température de polymérisation et est ensuite amené à passer vers une machine à stratifier où la mousse séchée est mise en contact avec un noyau de panneau de stratification non élastique et est polymérisé sur lui.
  14. Une sous-couche de mise de côté comprenant un noyau non-élastique de type traditionnel stratifié sur un bardage de la revendication 1.
  15. Un panneau isolant comprenant un noyau non élastique stratifié sur une surface d'un matelas non asphaltique et non-cellulosique contenant une faible proportion de fibres selon la revendication 1.
  16. Le panneau isolant de la revendication 15 dans lequel ledit tensioactif est un sel d'ammonium d'un acide gras en C10 à C22.
  17. Le panneau isolant de la revendication 16 dans lequel ledit sel est du stéarate d'ammonium.
  18. Le panneau isolant de la revendication 15 comprenant un noyau non élastique dans lequel les deux surfaces du noyau sont stratifiées sur un bardage de la revendication 1.
  19. Le panneau isolant de la revendication 15 comprenant un noyau non élastique dans lequel une surface du noyau est stratifiée sur le bardage de la revendication 1.
  20. Le panneau isolant de la revendication 19 dans lequel la surface opposée dudit noyau est stratifiée sur un matelas à contenance cellulosique ou asphaltique de type traditionnel.
  21. Le panneau isolant de la revendication 15 dans lequel le latex dudit latex est une résine à base acrylique.
  22. Le panneau isolant de la revendication 15 dans lequel ladite charge est un agent ignifuge.
  23. Le panneau isolant de la revendication 22 dans lequel ladite charge est de l'aluminium trihydraté.
  24. Le panneau isolant de la revendication 15 dans lequel ledit matelas contient moins de 50% en poids de fibres.
  25. Le panneau isolant de la revendication 24 dans lequel ledit matelas contient entre environ 30 et 46% en poids de fibres.
  26. Le panneau isolant de la revendication 15 dans lequel ledit bardage est un matelas de verre avec ladite mousse polymérisée en surface.
  27. Le panneau isolant de la revendication 15 présentant une épaisseur d'entre 0,5 et 10,2 cm (0,2 et 4 pouces).
  28. Le panneau isolant de la revendication 15 dans lequel ladite mousse polymérisée a une densité d'entre 0,1 et 0,4 g/cm3 (g./cc).
EP99945214A 1998-09-08 1999-08-26 Bardage en mousse et panneaux isolants qu'il permet de fabriquer Expired - Lifetime EP1115562B1 (fr)

Applications Claiming Priority (7)

Application Number Priority Date Filing Date Title
US376247 1982-05-10
US9945198P 1998-09-08 1998-09-08
US99451P 1998-09-08
US376275 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 (fr) 1998-09-08 1999-08-26 Bardage en mousse et panneaux isolants qu'il permet de fabriquer

Publications (3)

Publication Number Publication Date
EP1115562A2 EP1115562A2 (fr) 2001-07-18
EP1115562A4 EP1115562A4 (fr) 2001-11-21
EP1115562B1 true EP1115562B1 (fr) 2005-08-31

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EP99945214A Expired - Lifetime EP1115562B1 (fr) 1998-09-08 1999-08-26 Bardage en mousse et panneaux isolants qu'il permet de fabriquer

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EP (1) EP1115562B1 (fr)
JP (1) JP2002524316A (fr)
AT (1) ATE303245T1 (fr)
AU (1) AU5786699A (fr)
CA (1) CA2340451C (fr)
DE (1) DE69927038T2 (fr)
DK (1) DK1115562T3 (fr)
ES (1) ES2249025T3 (fr)
WO (1) WO2000014358A2 (fr)

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* Cited by examiner, † Cited by third party
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
FI3898226T3 (fi) * 2018-12-19 2023-10-04 Owens Corning Intellectual Capital Llc Ohutkerroksinen uv-kovettuva pinnoite kuitupäällysteiden päällä

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA1135127A (fr) * 1979-05-07 1982-11-09 George R. Ferment Procede de revetement de fibre tissee lache
EP0380651B1 (fr) * 1988-07-25 1998-03-25 Interface, Inc. Moquettes veloutees et carreau de moquette lies par fusion de latex
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 (ja) * 1992-04-15 1993-11-02 Matsushita Electric Works Ltd フェノ−ル樹脂成形体及びその製造方法
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

Also Published As

Publication number Publication date
EP1115562A2 (fr) 2001-07-18
CA2340451A1 (fr) 2000-03-16
DE69927038D1 (de) 2005-10-06
EP1115562A4 (fr) 2001-11-21
CA2340451C (fr) 2009-12-15
WO2000014358A3 (fr) 2000-06-08
DE69927038T2 (de) 2006-06-08
DK1115562T3 (da) 2006-01-02
ES2249025T3 (es) 2006-03-16
WO2000014358A2 (fr) 2000-03-16
ATE303245T1 (de) 2005-09-15
AU5786699A (en) 2000-03-27
JP2002524316A (ja) 2002-08-06

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