MXPA01002235A - Foamed facer and insulation boards made therefrom - 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

ALVEOLAR COATING PLATE AND INSULATION BOARDS ELABORATED FROM THE SAME BACKGROUND OF THE INVENTION Rigid polymer foam insulation laminates have been used for many years by the construction industry. Uses include commercial roof insulation boards used under integrated asphalt roof membranes (BUR) as well as under several single-fold membranes such as EPDM rubber, PVC, modified bitumen membranes and the like. Other uses • include residential insulation, as low-deck trim, and as roof insulation under asphalt shingles and concrete mosaics. Such insulation frequently takes the form of a central polymeric foamed or alveolar thermosetting 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 in production lines in which a liquid central chemical mixture is poured onto a bottom liner or bottom liner, foaming upon contact with a top liner sheet in a restricted overhead laminator. The reaction of the chemical mixture that Ref: 127328 causes foaming or foaming is generally exothermic, since curing via polymerization and crosslinking occurs in the mill. In the case of polyisocyanurate insulation boards, heat evolution lasts well at the time when the resulting rigid boards are cut, stacked and stored. The heat evolution can continue as long as 4 days and the mixture can reach temperatures as high as 162.8 ° C (325 ° F). 3 Desirable properties for cladding sheets include flexibility, high tensile strength and tear resistance and resistance to thermal degradation. The porosity of the veneer sheet must be low and the coating thickness of the veneer sheet must be sufficient to prevent the penetration of liquid chemical compounds prior to foaming or foaming. Additionally, the coating plates must exhibit good adhesion to the core foam insulation and be inert to the effects of foreign chemical components that may be present in the mixture, especially blowing agents that also behave as solvents. The blowing agents currently in use include chlorofluorocarbons such as HCFC-141b and R-22, also as hydrocarbons such as n-pentane, cyclopentane and iso-pentane.

A problem that has plagued the polyiso industry has been a phenomenon called "cold temperature delamination." This phenomenon occurs in areas of cold temperature where the insulation boards that leave the production line are cooled before they can be "cured in a pile". In a worst-case scenario, the central polyiso foam layer closest to the coating plate cools, turning off the curing reaction and leaving a brittle layer. This frequently leads to the cutting of the central layer or detachment of the covering sheet. It has been the practice of the manufacturers to place a layer of corrugated cardboard both on the upper surface of the top sheet of the top board and under the surface of the bottom sheet of bottom board in the pile, to retain the exothermic heat and prevent subsequent delamination. Thus, a coating sheet that inherently insulates and retains heat during pile curing would materially reduce delamination incidents at a cold temperature and eliminate the need for expensive cardboard insulation. After these honeycomb or foamed polymeric insulation boards are cured, cut and packed to their place of use, the coating sheet must provide mechanical stability as well as resistance to water and weathering since, after installation, they may be exposed to persistent rain, high humidity, ultraviolet light and excessive heat. Additionally, the cladding sheets must be puncture resistant and scratch resistant to survive the application of nails and walking. It has been found to withstand temperatures up to 260 ° C (500 ° F), in hot asphalt applications, as well as resistance to the damaging effects of adhesive solvents used in single-fold roof membrane applications as long as They stick strongly to the adhesives themselves are also important properties of the cladding sheet. Traditionally, cladding sheet materials have included saturated asphalt cellulose felts, fiberglass mats, fiberglass mats coated with asphalt emulsion, aluminum / Kraft foil / metal foil, fiberglass modified cellulose felts, glass mats on which polymer films and glass mats coated with polymer latex / inorganic binder coatings have been extruded. However, all these materials have at least one undesirable property. For example, asphalt-containing products are not compatible with single-ply PVC roof membranes. Fiberglass mats are subjected to excessive penetration of foamable core chemical compounds. The cladding sheets and aluminum sheets reflect heat to the foam during processing, which leads to deformation of the cell structure, delamination and ripple. In addition, the lining and extrusion or lamination of the aluminum cladding sheets from a polymeric film to glass mat surfaces is expensive. Specifically, it has been found that glass mats coated with polymeric latex / inorganic binder mixtures are susceptible to moisture absorption, aggravating board ripple in damp or wet environments. Other cladding sheets that have been used for boarding enhancement and insulation board cladding sheets include those described in U.S. Patent Nos. 5,76,841 and 5,717,012 which are primarily felts. U.S. Patent No. 5,001,005 discloses a sheet of sheet metal composed of glass fibers and a non-asphalt binder. The coating plate contains 60-90% glass fibers, such high fiberglass content does not provide sufficient binder to close the pores of the sheet or to provide desired sheet strength. U.S. Patent No. 5,102,728, which discloses a glass mat substrate coated with a polymeric latex mixed with an asphalt emulsion, is concerned with a product that is not only incompatible with PVC roofing membranes, but also requires a Excess coating thickness to reduce high porosity. Thus, this product is very expensive. U.S. Patent No. 5,112,678 discloses a coating sheet prepared by applying a flowable polymer latex and an inorganic binder coating to a glass fiber mat. The resulting product is somewhat brittle and is susceptible to an undesirable degree of penetration of the chemical compound. U.S. Patent Nos. 5,698,302 and 5,698,304 disclose coating plates wherein polymeric films are laminated or extruded onto glass fiber mat. Not only is this process expensive, but also, since polymers filled with conventional mineral flame retardant do not extrude well, some degree of flammability resistance must be sacrificed. Thus, it is an object of this invention to overcome the above disadvantages and deficiencies and to provide a cladding sheet that is produced economically and by a process commercially feasible. It is also an object to provide a mechanically suitable stable cladding sheet for the manufacture of the insulation board that resists cold-weather delamination and that has superior tolerance to the effects of weathering. Another object is to provide a cladding sheet that exhibits superior adhesion to polyiso foam of a core material or core material of insulation board. These and other objects and advantages of the invention will become apparent from the following description and disclosure.

BRIEF DESCRIPTION OF THE INVENTION The non-asphalt, non-cellulosic coating plate of the present invention comprises a dry preformed fibrous mat substrate on which a pre-foamed or pre-alveolar composition containing a natural or synthetic thixotropic latex polymer is coated. , a surfactant and an inorganic mineral filler. The composition may optionally contain up to about 15% by weight of foreign additives, which include a flame retardant, dye, thickener, viscosity reducing agent, thermal stabilizers and / or UV stabilizers and the like, to provide a foamed sheet metal product. or alveolar that has, on a dry weight basis, less than 50% fiber in the mat. The preferred coating sheet product contains 30% to 46% by weight of fiber in the composition consisting of mat fiber with binder and latex in the coating mixture.

DETAILED DESCRIPTION OF THE INVENTION In general, the foamed or alveolar coating composition applied to the preformed mat contains, on a dry weight basis, between about 15 and about 80% by weight of the thixotropic polymer latex, between 0.01 and about 80% by weight. fill weight, between about 0.5 and about 10% by weight of surfactant that supports the foam and 0 to 15% by weight of foreign additives. The mat fibers employed in this invention include any of the non-cellulosic types, such as glass fibers, polyester, polypropylene, polyester / polyethylene / terephthalate copolymers, hybrid types such as polyethylene / glass fibers and other conventional non-cellulosic fibers. . Mats having glass fibers in disordered 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 between about 0.0254 cm (10 mils) and about 0.0762 cm (30 mils) thick, conventionally contain a binder that is incorporated during mat formation to fix the fibers in a self-held solid tape or fabric and to prevent the loss of fibers during subsequent processing and handling. Such binders include phenol-, melamine- and / or urea-formaldehyde resins or mixtures thereof. Most preferred are mats having glass fibers in the range of about 3 to about 20 microns, more desirably 10-18 microns in diameter and a length of about 0.635 cm (0.25 inches) to about 4.45 cm (1.75 inches) ), more desirably a length of 1.9 cm - 3.8 cm (0.75-1.5 inches). The fillers useful in the present coating mixture include conventional inorganic types such as clays, mica, talc, lime, kaolin, other stone powders, gypsum, aluminum silicate (for example Ecca Tex 561), flame retardant aluminum trihydrate, ammonium sulphamate , antimony oxide, calcium silicate, calcium sulfate and mixtures thereof. The surfactants used in the coating composition are organic types suitable for crosslinking stabilization, such as, for example, ammonium salts of a fatty acid of 10 to 20 carbon atoms, for example ammonium stearate (STANFAX 320). One or more surfactants can be employed in the coating composition to promote foaming and to maintain the foam structure of the coating during curing. The latex component of the coating composition includes natural rubber latex polymers, also as synthetic cross-links 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 thereof. The mat coating mixture of the invention is obtained from a 15-80% by weight foamed or foamed aqueous emulsion, dispersion or suspension, which is pre-foamed by incorporating air into the aqueous liquid mixture, for example by blowing or mixing, with vigorous stirring in the presence or absence of a conventional blowing agent. Then, the resulting foamed or foamed alveolar composition is coated to a thickness of about 0.0127 cm (5 mils) to about 0.254 cm (100 mils) on the preformed mat surface under ambient conditions using a spatula, a roller or any other convenient application method. In one aspect, the foam-coated mat is then dried at a temperature less than its curing temperature to provide a self-supporting foamed or foamed product having a reduced coating thickness of up to 0.2286 cm (90 mils) that adheres to the mat surface. In another aspect, the foam-coated mat is dried and cured simultaneously. The resulting sheet metal product of this invention is desirably flexible and possesses low permeability to liquid chemicals used for insulation cores also as superior dimensional stability and high tensile strength after curing. This product, which comprises the mat having an adhered surface coating of a pre-foamed latex / filler / surfactant, can be fed directly to the manufacture of the insulation board, for example a restricted high laminator, wherein the uncoated fiber surface The mat is contacted with at least one exposed surface of a foamable or foamable non-elastomeric thermoplastic core in the manufacture of an insulation board as described hereinafter.

As indicated above, the foamed or alveolar coating of the present coating sheet can be formed in the absence or presence of a blowing agent to provide a reduced density composition, such density can be reduced from about 2 g / cc to a density as low as 0.15 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 the shaving cream. In general, the amount of air incorporated into the foamable mixture before coating is between about 5% and about 80% by volume for optimum consistency and the resulting foamed mixture has sufficiently small bubble openings or holes to inhibit penetration through of the mat. The application of a film or lamination of a waterproof polymer or resin layer on the foamed surface to provide a three layer coating sheet element can provide a surface totally impervious to liquid on the coating sheet, in special cases where such it is desired A top-seal coating of a non-foamed or non-foamed latex is appropriate for this purpose. Alternatively, a thermoplastic such as a polyethylene powder or unexpanded polystyrene beads can be used as a filler that melts at the drying / curing temperatures to close substantially all pores of the permeable coating. Excipients and expandable additives such as cellulose can also be used for this purpose; although the use of a sealing coating is neither necessary nor recommended. Other methods to accomplish the similar purpose include the use of less air during foaming or foaming, the omission or use of less organic filler in the coating composition, calendering and / or embossing or etching of the foamed or honeycomb surface. by contact with a hot roller or plate. Yet another method for producing the fully waterproof 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 used for special purposes if desired. In the present case, the coating sheet of the invention having a foamed cellular coating, contains latent exothermic energy and has a higher potential thermal capacity upon entering the laminator; thus decreasing the curing time of the lamination and prolonging the generation of heat by acting as an insulator during curing in the post-curing stack. This advantage eliminates the need for elements that retain heat at the top and bottom of the stack and significantly reduces the problem of the prior art of the susceptibility of the board to cold temperature delamination. Further, where the foamed coating or honeycomb coating on the coating sheet is dried and / or cured, the adhesion strength between the uncoated fibers and the core material in the resulting product is improved due to the reduced penetration of the mixture. of coating to the mat because of its pre-foamed state. Where the foam of the coating sheet is completely cured before entering the laminator, the core material is either poured onto the uncoated fibrous surface of the coating sheet or laminated thereon with a bonding agent or bonding agent. . Any pressure that can be applied during the lamination in the manufacture of the insulation board is less than that required to cause a 50% reduction in the thickness of the foamed or alveolar sheeting and insufficient coating to result in damage or crushing of the fiber mats in the finished insulation board product. The weight of the present coating sheet can vary from about 40 to about 300 g / square meter and the sheet of the foamed sheet can have a thickness of up to about 0.254 cm (100 thousandths of an inch), depending on the consumer's preference. For certain purposes that demand stronger coating plates, crosslinks can be selected. The present latex coating composition can additionally contain a minor amount, up to 15%, preferably less than about 3% by weight of a conventional thickening agent, for example an acrylic polymer thickener, for example (ACRYSOL ASE 95NP and / or 60NP) and the like. Other excipients such as a UV stabilizer or thermal stabilizer, a conventional coloring agent, texturizing agent, reinforcing or crosslinking agent (for example CYMEL 303 resin) and / or blowing agent can also be included in the mixture of covering; although the addition of these additives in a minor amount of less than 2% by weight is preferred. Insulation boards, for which the present coating sheet is particularly suitable, comprise thermosetting foam cores or centers or conventional thermoplastics, such as foamed or foamed polyurethane or polyurethane modified polyisocyanurate cores or phenol-formaldehyde cores arranged between a pair of cladding sheet elements that are laminated to the core surfaces. Other non-elastomeric foamable chemical compounds, such as polyvinyl chloride, polystyrene, polyethylene, polypropylene and others conventionally employed as core material may also be employed as the core of the insulation board of this invention. Rigid foamed or alveolar cores of this type are described for example in U.S. Patent 4,351,873, incorporated herein by reference. The cladding sheets present are also suitable for the lining of a boarding up to a thickness of up to about 2.54 cm (1 inch) and composed of a core material or non-elastic core material of a chemical or chemical mixture similar to that of the isolation core. The use of the present veneer sheet eliminates the need for expensive metal sheet facing sheets that retain and reflect heat and often cause ripple and deterioration of wood enhancement. Also, sheet metal cladding sheets and similar cladding sheets are easily perforated, which gives rise to moisture attack. In the manufacture of the insulation, a roll of the present foamed or foamed sheet metal sheet product is passed, with its uncoated fiber surface opposite the core surface, to a rolling zone. The chemical component or mixture of chemical compounds, precursor of the central foam or core foam of the board can be poured on the uncoated fiber surface of the sheet of the cladding sheet or the core of the insulation board can be pre-foamed to a self-sustained consistency. In one embodiment, a first cladding sheet of this invention, with its uncoated surface spliced to the core, is placed beneath the core. The fiber surface of a second veneer sheet is positioned and spaced above the core to allow expansion of the core, for example in a restricted elevated mill, where the assembly undergoes an exothermic reaction and curing is initiated. During the curing operation, the core material is foamed and raised to contact the uncoated lower surface of the second coating sheet. It will be understood that one of the first and second coating sheets may be the same or a different composition than that of this invention; although it is preferred that both of these coating plates are those of the invention described herein. More specifically, one of the sheets of veneer sheet can be selected from those conventionally used, such as for example a sheet of cellulose or hybrid felt of cellulose-glass, pearlite, aluminum foil, multi-laminated sheet metal sheets and Kraft, uncoated or coated fiberglass mats; although the second sheet of the coating sheet of the present invention improves the advantages described herein. As the core foam or core foam is spread on the fibrous surface of the first sheet of facing sheet entering the laminator, it experiences an exothermic reaction that can reach a temperature of up to about 93.3 ° C (200 ° F) . The core foam rises to contact the lower surface of the second cladding sheet and hardens on it; thus providing a core of rigid insulating foam interposed or sandwiched between two sheet metal sheets. Then the resulting product can be cut into boards of desired size and shape. The heat of the exothermic reaction involving polymerization and / or crosslinking is self-generated both in the laminator and in the subsequent piling of the insulation boards to ensure complete curing of the core and surface coating of the coating sheet. Curing temperatures during stacking can be raised to approximately 162.8 ° C (325 ° F) for a period of up to 4 days. As another embodiment involving the above operation, the upper and lower positioning of the sheets of facing sheet can be reversed in such a way that the facing sheets of this invention are fed and spaced above conventional facing sheets in a manner such that its uncoated fibrous surfaces are facing the foamable insulating central chemical compound which is brought into contact with its lower surface with another sheet of facing sheet. The last process is carried out in practice where a lining sheet is a woven sheet, as in a perlite board or particleboard facing sheet in opposite position to the flexible lining sheet of this mention which can be fed to the laminator as a continuous roll. In this case, the foamable insulating central chemical compound is coated on the rigid cladding sheet member and raised to mate with the uncoated fibrous surface of the present cladding sheets. The latex of the surface layer of the present veneer sheet which, due to its comparatively thick latex foam and low fiber to latex coating ratio, more efficiently retain the heat between the layers of the roll. From here, the lamination of the core can be completed at a faster speed and the stack can be carried out without damage to the laminate. Additionally, it is now found that this heat retention during curing improves the bonding of the core and significantly reduces the subsequent "cold temperature delamination" in the product, which is caused by failures of the top layer of the insulation to full curing due to the exposure to colder temperatures during stacking after leaving the laminator. Insulation boards incorporating the present cladding sheets are useful in commercial roof insulation, residential or commercial wall cladding, etc. Depending on the proposed use, the present insulation board has a central thickness that can vary widely, for example between about 1.27 cm (0.5 inches) and about 10.16 cm (4 inches) or more. In the above description, it will be apparent that it is also possible to form the insulation core separately, that is, absent contact with the fibers of a coating sheet and subsequently gluing one or more coating sheets present to the core using appropriate adhesives. In general, the teachings of U.S. Patent 4,351,873 are applicable to the formulation of rigid foam cores and adhesion of the sheets of coating sheet to at least one surface of such cores. This method is incorporated herein by reference.

Polyurethane or polyisocyanurate are more commonly used as core materials; although other non-elastomeric foamable chemical compounds are also employed. Examples of the latter include polyvinyl chloride, polystyrene, phenolic resins and the like. The coating sheets and insulation board products of this invention exhibit significantly higher tensile strength than those containing 60-90% by weight of fibers. The cladding sheets present also have resistance to cracking at low temperatures and exceptionally superior dimensional stability and fire retardancy. Due to its superior strength and flexibility, the present coating sheet can find a wider application, such as in glare-free linings, if not as a sub-layer of shingle, separation or barrier sheets and the like.

EXAMPLE 1 A 473 ml metal can with a low shear mixer was used to combine a 51.5% aqueous solution of a self-crosslinkable acrylic latex (Room &Haas, E-693), a slurry or slurry of aqueous clay 23.5% (Ecca Tex 561) a mixture of a melamine crosslinking agent (CYMEL 303), an ammonium stearate foam stabilizer (STANFAX 320), an acrylic polymer thickener (Acrysol ASE 95NP) and black pigment of carbon in amounts shown in the following table 1. The above ingredients were thoroughly mixed for approximately 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 or alveolar mixture, using an LVT # 4 spindle at 30 revolutions per minute, was 1500 cps.

* Ammonium stearate. The previous foamed latex mixture was coated on the upper surface of a preformed fiberglass mat containing 27.5% by weight of urea-formaldehyde binder and having 72.5% by weight of 3,175 cm filaments (1 1/4 inch) average of 15.9 microns of average diameter. The coating was carried out using a Gardner drawing equipment to obtain a coating thickness of 0.0762 cm (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 the previous coating sheet sample were compared with those of the commercial samples A, B and C and the results were as recorded in table 2.

Example 2 Example 1 was repeated except that the self-crosslinkable acrylic (RHOPLEX B-959) was replaced by latex (E-693) and the prealveolar or pre-foamed dry mix on the mat was not cured. The non-foamed or non-foamed mixture of this example had a Brookfield viscosity of 3600 cps. The uncured foam coated mat of this example was introduced to a laminator where the undersurface of the uncoated fiber of the mat was brought into contact with a core of polyurethane / alveolar isocyanurate of an insulation board and the curing was initiated simultaneous foam mat and core. After approximately 1-2 minutes in the laminator at a temperature of approximately 120 to 200 ° C the laminated board was cut into boards of 1.22 mx 2.44 m (4 x 8 feet) and the squares of boards piled in units of 25 elements for Complete the cure in a period of 2.5 days.

Example 3 Example 1 was repeated except that 45 g of aluminum trihydrate (ALCOA GRADE C-320) were added to the coating mixture to increase the flame retardancy of the coating sheet. The Brookfield viscosity of the unfoamed mixture was 2,200 cps and the foam had a density of 0.23 g / cc. Conventional coating plates most commonly used are uncoated cellulose fiber mats that may or may not be reinforced with a smaller amount of glass fibers. In table 2, examples A and B represent this type. Example A is reinforced with 18% glass fibers 3,175 cm (1 inch) long, Example B is reinforced by 13% glass fibers less than 0.3175 cm (1/8 inch) long. Another type of commercially successful veneer sheet comprises a glass mat on which a polyethylene coating has been extruded. A cladding sheet of this type is represented as sample C. The properties of all cladding sheets in the above examples are reported in the following table 2. Table 2 Property Example 1 Example 2 Example 3 Commercial A Commercial B Commercial C Base weight, 13.1 1133..11 15.27 19.6 22.0 11.2 pound / 480 square feet caliber, cm 0.08889 (35) 0.0889 (35) 0.0889 (35) 0.0457 (18) 0.0457 (18) 0.0330 (13) (thousandths of an inch (ASTM D-146-90)% fiber 41.6 41.6 35.7 90 90 68.3 Tensile strength, lbs / inch (ASTM D-146-90) DM 45.8 44.6 45.4 29.8 42.8 33 CDM 44.9 33.1 30.2 18.5 17.6 Tear strength of Elmendorf g-ñierza (ASTM D-689-79 DM 390 387 384 238 132 CMD 457 518 433 395 167 Resistance to 60 - - 30 27 Mullen burst Dimensional stability (% expansion from dry to wet) DM 0.02 0.02 0.02 0.13 0.30 CMD 0.02 0.02 0.02 0.69 1.80 The above examples are representative and it will be understood that they can be make many alterations and substitutions therein without departing from the scope of this invention Reference is made defining the invention to the appended claims It is noted that, with respect to this date, the best method known to the applicant to carry the practice said invention is that which is clear from the present description of the invention.

Claims (30)

1. CLAIMS Having described the invention as above, the content of the following claims is claimed as property. A flexible, low fiber content coating sheet suitable for use in building construction and containing less than 50 wt.% Fiber, characterized in that it comprises a mat substrate of non-cellulose, non-asphaltic fiber, between approximately 0.0254 cm (10 thousandths of an inch) and approximately 0.0762 cm (30 thousandths of an inch) of thickness in contact with a surface matting of 0.0127 cm (5 mils) to 0.254 cm (100 mils) of a thickness of between about 15 and about 80% by weight of a foamed or foamed mixture containing, on a dry weight basis, (a) between about 15 and about 80 by weight of a thixotropic polymeric latex, (b) a reinforcing amount or flame retardant inorganic filler and (c) a foam holding amount, of foam construction of an organic surfactant.
2. 2. The coating sheet according to claim 1, characterized in that (b) is between about 0.01 and about 80% by weight of the mixture.
3. 3. The coating sheet according to claim 1, characterized in that (c) is between about 0.5 and about 10% by weight of the mixture.
4. 4. The coating sheet according to claim 1, characterized in that the fiber of the mat is fiberglass.
5. 5. The coating sheet according to claim 4, characterized in that the fibers have an average diameter of between about 3 and about 20 microns and a length of between about 0.635 cm (0.25 inches) and about 4,445 cm (1.75 inches).
6. 6. The coating sheet according to claim 1, characterized in that (c) is an ammonium salt of a fatty acid of 10 to 22 carbon atoms.
7. 7. The coating sheet according to claim 6, characterized in that (c) is ammonium stearate.
8. 8. The coating sheet according to claim 1, characterized in that the latex of the coating mixture is an acrylic based resin.
9. 9. The coating sheet according to claim 1, characterized in that the coating mixture additionally contains up to 15% by weight of an excipient selected from the group of a thickener, a coloring agent, a texturizing agent, a light stabilizer. ultraviolet, a thermal stabilizer, a flame retardant, a weathering agent and a blowing agent.
10. 10. The coating sheet according to claim 9, characterized in that an ultraviolet light stabilizer is present in an amount of up to about 2.5% by weight of the mixture.
11. 11. The cladding sheet according to claim 1, characterized in that the cladding sheet contains 30 to 46% by weight of fiber.
12. 12. The coating sheet according to claim 1, characterized in that the coating has a density between about 0.1 and about 4 g / cc. A process for the preparation of the coating sheet according to claim 1, characterized in that it comprises: (a) forming an aqueous mixture of 15 to 80% by weight of the coating composition, (b) foaming the mixture to a self-sustaining consistency; (c) apply a uniform coating of 0.0127 cm (5 mils) to 0.2032 cm (80 mils) of the foamed mixture to a surface of the mat, (d) 'dry the resulting mat and ( e) recovering the dry foam coated mat having a fiber concentration of less than 50% by weight as the product of the process. The process according to claim 13, characterized in that the foam-coated coating sheet is dried and cured and then passed to a rolling mill for lamination to a non-elastic insulation board core or core. 15. The process according to claim 13, characterized in that the foam coated coating sheet is dried at a temperature lower than its curing temperature and then passed to a laminator where the dry foam is contacted with a core of non-elastic lamination board and cured about it 16. A siding enhancement, characterized in that it has a conventional, non-elastic core laminated to a siding sheet according to any of claims 1, 2 or 3. 17. An insulation board, characterized in that it has a non-elastic laminated core. on a surface to a non-asphaltic and non-cellulosic mat containing a low fiber content according to claim 1. 18. The insulation board according to claim 17, characterized in that the surfactant is an ammonium salt of an acid fat of 10 to 22 carbon atoms. 19. The insulation board according to claim 18, characterized in that the salt is ammonium stearate. 20. The insulation board having a non-elastic core, characterized in that both surfaces of the core are laminated to a cladding sheet in accordance with claim 17. 21. The insulation board having a non-elastic core, characterized in that a surface The insulation board according to claim 21, characterized in that the opposite surface of the core is laminated to a mat containing conventional cellulose or asphalt. 23. The insulation board according to claim 17, characterized in that the latex is an acrylic-based resin. 24. The insulation board according to claim 17, characterized in that the filling is a flame retardant agent. 25. The insulation board according to claim 24, characterized in that the filler is aluminum trihydrate. 26. The insulation board according to claim 17, characterized in that the glass mat covered with foam contains less than 50% by weight of fiber. 27. The insulation board according to claim 26, characterized in that the glass mat covered with foam contains between about 30 and about 46% by weight of fiber. 28. The insulation board according to claim 17, characterized in that the coating sheet is a glass mat coated with the cured foam. 29. The insulation board according to claim 17, characterized in that it has a thickness between about 0.51 cm (0.2 inches) and about 10.16 cm (4 inches). 30. The insulation board according to claim 17, characterized in that the cured foam has a density between about 0.1 and about 0.4 g / cc.