GB2032843A - Foamed phenolic board laminate - Google Patents

Foamed phenolic board laminate Download PDF

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Publication number
GB2032843A
GB2032843A GB7842522A GB7842522A GB2032843A GB 2032843 A GB2032843 A GB 2032843A GB 7842522 A GB7842522 A GB 7842522A GB 7842522 A GB7842522 A GB 7842522A GB 2032843 A GB2032843 A GB 2032843A
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GB
United Kingdom
Prior art keywords
tissue
strength
core
board according
glass fibre
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.)
Granted
Application number
GB7842522A
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GB2032843B (en
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Coal Industry Patents Ltd
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Coal Industry Patents Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Coal Industry Patents Ltd filed Critical Coal Industry Patents Ltd
Priority to GB7842522A priority Critical patent/GB2032843B/en
Publication of GB2032843A publication Critical patent/GB2032843A/en
Application granted granted Critical
Publication of GB2032843B publication Critical patent/GB2032843B/en
Expired legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/20—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
    • E04C2/205—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics of foamed plastics, or of plastics and foamed plastics, optionally reinforced
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0285—Condensation resins of aldehydes, e.g. with phenols, ureas, melamines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/08—Closed cell foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Architecture (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

An insulating board of excellent properties is made from a core of foamed phenol-formaldehyde resin which has a closed cell content of at least 85% and on at least one face a glass fibre tissue or cloth laminated to the core using a water-based natural rubber adhesive. Essential properties relating to the water absorption, thermal conductivity, flexural strength, compressive peel strength and delamination peel strength of the laminate are specified. The laminate has excellent fire resistance and may comprise, in the adhesive, a fungicide and an anti-oxidant.

Description

SPECIFICATION Phenolic board laminate This invention concerns a laminated insulation board.
It is known to make insulation boards from foamed plastics, and some of these are laminated with other materials to give properties desirable for use in building or construction work. In particular, it is known to use phenol-formaldehyde boards in roof insulation, but it is believed that commercially available phenol-formaldehyde boards have up to now been of open-cell construction.
The present invention provides a laminated insulating board comprising an insulating core of foamed phenol-formaldehyde resin which has a closed cell content of at least 85% and on at least one face a glass fibre woven or non-woven cloth or tissue laminated to the core'with a water-based natural: rubber latex adhesive, the laminate having a water absorption of not more than 10% v/v, a thermal conductivity (k-value) of less than 0.035 W/mOC a flexural strength of at least 50 x 104 N/m2, a tensile strength of at least 30 x 104 N/m2, a compressive strength of at least 20 x 104 N/m2 and a delamination peel strength of at least 200 N/m at room temperature.
It is believed that the combination of properties essential to success in practical usage can only be obtained with a laminate as specified above, and it is essential to use the natural rubber adhesive, to achieve a satisfactory product. It is preferred that the laminate of the invention is a sandwich form, in that it is laminated with glass fibre on two opposing major faces.
The core of foamed phenol-formaldehyde may be manufactured without difficulty; several manufacturers sell phenol-formaldehyde resoles which are intended for foaming. A blowing agent, such as a "Freon" Registered Trade Mark blowing agent, is conventionally used, as is a hardener, such as an acid, e.g. hydrochloric acid. It is advantageous to use a cell control agent, and a silicone oil surfactant may be used. As has been stated above, a very high closed cell content is believed essential, and manufacture may be controlled in known manner to achieve this.
The glass fibre cloth or tissue is preferably a non-woven tissue, which is commercially available.
The preferred tissue has a thickness of 0.25 to 0.60 mm, a weight of 40 to 80 g/m2 and a tensile strength of 1 5 to 40 N/m2. The tissue improves the strength and the dimensional stability of the insulating board, yielding results in combination with the rubber adhesive which are unexpectedly good.
It is essential to use a natural rubber latex adhesive, which may be thickened to a convenient viscosity (e.g. to 5,000 1 5,000 cps at 200C for application using a roller coater applicator) using a polyacrylate thickening agent. Since insulation boards are frequently exposed to damp, for example from condensation, it is preferred to incorporate a fungicide to prevent fungal growth and possible loss of strength. Also, since the insulation boards of the invention may be exposed to high temperatures, by reason of their being applied to a structure using molten bitumen (at about 1 50 C) or because of solar gain, it is preferred to stabilise the natural rubber adhesive with the addition of an anti-oxidant.The adhesive has to give a high bond strength between the phenolic foam core, which is of low density, dusty and friable, and the glass fibre cloth or tissue. The bond has to withstand wind suction on flat roofs in severe gales, and it has been found that a minimum peel strength of 200 N/m is required. In addition, the adhesive must exhibit minimum degradation at temperature extremes of 0 C and +900C and be unaffected by moisture and dilute acids; it must also withstand contact with hot melt bitumen and asphalt at temperatures up to 2500C.
An extremely wide selection of adhesives were assessed for compliance with the above requirements, including essentially all commercially available elastomeric polymers, vinyl - and acrylic - based adhesives etc. To the surprise of the inventors, only natural rubber was found to be totally suitable, although of course other adhesives met some or almost all of the criteria. Most of the failures were caused in a test involving contact with hot bitumen or a 900C high temperature delamination test.
It was decided that a water-based adhesive was required for both economic reasons and for practical usage; six were tested for their ability to bond glass fibre tissue to phenolic foam and durabiiity when subjected to specific ageing tests. The results for peel strength are given in the table below.
Adhesive Peel Strength (N/m) Poly Vinyl Styrene Butadiene Nitrile Neoprene Natural Acetate Rubber Rubber Rubber Acrylic Rubber At ambient 94 300 640 172 194 325 After 30 days at 90 C 143 21 150 120 185 105 After 30 days at -10 C 110 142 200 160 90 320 After 30 days cycle test 41 24 322 120 189 305 (Note) Note: The cycle test involves holding the test pieces for 24 hours at 90 C, 50 C and 100% Relative Humidity and at -10 C respectively for a total period of 30 days.
Nitrile rubber performed extremely well in these peel strength tests: it was, however, the poorest of the six adhesives in shear strength and could not therefore meet the overall requirements set by the inventors. Many commercial adhesives failed to give a bond strength of even 50 N/m or broke down on contact with water, or could not withstand hot bitumen at 2500C and so were not evaluated to the same extent as the six mentioned in the table above.
The invention will now be illustrated by means of an example.
A phenol formaldehyde resole resin of low reactivity and low free phenol content, having a specific gravity of 1.20 to 1.25 g/cc and a viscosity at 200C in the range 3,000 to 6,000 cps, is thoroughly mixed in a batch with a surfactant such as a long chain fatty acid or a silicone, an acid hardener (conveniently hydrochloric acid or p-toluene sulphonic acid) and a low boiling point liquid blowing agent, such as pentane or trichlorofluoromethane. The proportions of the ingredients are: P/F resin 30 Kg Surfactant 0.3 Kg Hydrochloric Acid 3 Kg Pentane 2 litres.
The batch mixture is poured into a mould of dimensions 1.25 m x 0.65 m x 1 m which is then heated at 40 -- 500C for 3 - 4 hours. The batch foams and hardens, and the foam block resulting is removed from the mould and allow to cool for 2 days. The block is then cut into panels or boards of size 1.2 m x 0.6 m x 25 mm. The dry foam density is 35 40 Kg/m3.
A thickened natural rubber adhesive, having a viscosity in the range 5,000 -- 15,000 cps at 200C is applied on both major sides of individual foam boards by a roller coater. To the adhesive is applied a glass fibre non-woven tissue of 0.40 mm thickness, 60 g/m2 weight and having a tensile strength of 25 x 102 N/m, to give a laminated foam board.
The laminated board was tested for physical properties in comparison with an unlaminated board.
Test Foam Board Laminated Board Compressive Strength/Puncture (1) (N/m2) 22 x 104 22 x to4 Puncture Resistance (1) (N/m2) Very low 43 x 104 Flexural Strength (1) (N/m2) 30 x 104 60 x 104 Tensile Strength (1) (N/m2) 18 x 104 35 x 104 Dimensional Stability (2) (%) at 50 C -0.1 + 0.02 7QiC -0.5 + 0.02 90'C -0.6 - 0.04 50 C/100% relative -0.1 0.02 humidity Total Shrinkage, 24 hrs b 70'C (1) 0.7 0.1 Laminate Flexing test (3) at O3C (delamination) - None at 20-C (delamination) - None Foam Porosity VVater absorption (3) (% v/v) - 7.8 Vapour transmission (4) perm/inch - 1.9 Peel Strength (5) (N/m) At Ambiant Temp. - 220 After 30 days at -10C - 215 30 days cycle test (6) - 227 After 30 days at 90"C - 60 ditto, using antioxidant in adhesive - 180 Notes: (1) Tests from British Standards 3927 and 4370.
(2) B53927, modified to include greater number of temperatures.
(3) Test devised by inventors.
(4) B52972 (5) ASTM D773-47 (6) 24 hrs at 90 C, 24 hrs at 500C /100% RH and 24 hrs at -10 C, for total period of 30 days.
It will be readily seen from the above that the laminated board according to the invention shows significantly superior properties to those of the unlaminated board, and the improvement is greater than could be expected from a consideration of the properties of the glass fibre tissue.
In addition, the laminated board according to the invention shows very good resistance to heat and fire. It will char rather than burn. Unlike many insulating plastics foams, it will not melt or produce dense smoke, nor will it give off amines, cyanides, sulphur dioxide or other toxic gases. Tested according to B5476 for surface spread of flame, it achieved a nil flame spread (Class 1 ) and tested for ignitability it achieved the highest rating available (not easily ignitable).
Clearly, the thickness of the board, and other dimensions, can be varied according to the requirements of the user.

Claims (6)

1. A laminated insulating board comprising an insulating core of foamed phenol-formaldehyde resin which has a closed cell content of at least 85% and on at least one face a glass fibre woven or non-woven cloth or tissue laminated to the core with a water-based natural rubber latex adhesive, the laminate having a water absorption of not more than 10% v/v, a thermal conductivity (k-value) of less -than 0.035 W/mOC, a flexural strength of at least 50 x 104 N/m2, a tensile strength of at least 30 x 104 N/m2, a compressive strength of at least 20 x 104 N/m2 and a delamination peel strength of at least 200 N/m at room temperature.
-
2. A board according to claim 1, wherein the core is laminated with the glass fibre tissue or cloth on two opposing major faces.
3. A board according to claims 1 or 2, wherein a glass fibre non-woven tissue is used.
4. A board according to claim 3, wherein the tissue has a thickness of 0.25 to 0.60 mm, a weight of 40 to 80 g/m2 and a tensile strength of 1 5 to 40 N/m2.
5. A board according to any one of the preceding claims, wherein the adhesive comprises a fungicide and an anti-oxidant.
6. A board according to claim 1, substantiatly as hereinbefore described.
GB7842522A 1978-10-31 1978-10-31 Foamed phenolic board laminate Expired GB2032843B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB7842522A GB2032843B (en) 1978-10-31 1978-10-31 Foamed phenolic board laminate

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB7842522A GB2032843B (en) 1978-10-31 1978-10-31 Foamed phenolic board laminate

Publications (2)

Publication Number Publication Date
GB2032843A true GB2032843A (en) 1980-05-14
GB2032843B GB2032843B (en) 1982-07-14

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GB7842522A Expired GB2032843B (en) 1978-10-31 1978-10-31 Foamed phenolic board laminate

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2182607A (en) * 1985-09-19 1987-05-20 Geoffrey Crompton Building components
EP1072396A2 (en) * 1999-07-30 2001-01-31 Kawasaki Jukogyo Kabushiki Kaisha Sandwich structure and method of repairing the same
FR3028871A1 (en) * 2014-11-25 2016-05-27 Saint-Gobain Adfors WALL AND CEILING COATING AND METHOD OF MANUFACTURE.

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2182607A (en) * 1985-09-19 1987-05-20 Geoffrey Crompton Building components
GB2182607B (en) * 1985-09-19 1990-05-09 Geoffrey Crompton Fire-resistant components
EP1072396A2 (en) * 1999-07-30 2001-01-31 Kawasaki Jukogyo Kabushiki Kaisha Sandwich structure and method of repairing the same
EP1072396A3 (en) * 1999-07-30 2001-11-07 Kawasaki Jukogyo Kabushiki Kaisha Sandwich structure and method of repairing the same
US6770349B2 (en) 1999-07-30 2004-08-03 Kawasaki Jukogyo Kabushiki Kaisha Sandwich structure and method of repairing the same
FR3028871A1 (en) * 2014-11-25 2016-05-27 Saint-Gobain Adfors WALL AND CEILING COATING AND METHOD OF MANUFACTURE.

Also Published As

Publication number Publication date
GB2032843B (en) 1982-07-14

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