US20050042436A1 - Composite foam products and method - Google Patents

Composite foam products and method Download PDF

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Publication number
US20050042436A1
US20050042436A1 US10/489,014 US48901404A US2005042436A1 US 20050042436 A1 US20050042436 A1 US 20050042436A1 US 48901404 A US48901404 A US 48901404A US 2005042436 A1 US2005042436 A1 US 2005042436A1
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Prior art keywords
sheets
fiberglass
foam
consolidated
foam product
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Abandoned
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US10/489,014
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English (en)
Inventor
Sammie Glorioso
James Burgess
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IP Rights LLC
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IP Rights LLC
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Priority to US10/489,014 priority Critical patent/US20050042436A1/en
Assigned to APACHE PRODUCTS COMPANY reassignment APACHE PRODUCTS COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BURGESS, JAMES H., GLORIOSO, SAMMIE J. (JOEY)
Assigned to IP RIGHTS, LLC reassignment IP RIGHTS, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: APACHE PRODUCTS COMPANY
Publication of US20050042436A1 publication Critical patent/US20050042436A1/en
Priority to US11/786,921 priority patent/US20070193677A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
    • B29C44/32—Incorporating or moulding on preformed parts, e.g. linings, inserts or reinforcements
    • B29C44/326—Joining the preformed parts, e.g. to make flat or profiled sandwich laminates
    • 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
    • B32B5/18—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
    • 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
    • B32B5/26—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 also being fibrous or filamentary
    • 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
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/296—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B2038/0052—Other operations not otherwise provided for
    • B32B2038/0084—Foaming
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/04—Punching, slitting or perforating
    • B32B2038/047—Perforating
    • 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
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester 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
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/14—Mixture of at least two fibres made of different materials
    • 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
    • B32B2266/0278—Polyurethane
    • 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
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/08—Reinforcements
    • 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
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/17—Surface bonding means and/or assemblymeans with work feeding or handling means
    • Y10T156/1788—Work traversing type and/or means applying work to wall or static structure
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249962—Void-containing component has a continuous matrix of fibers only [e.g., porous paper, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249962—Void-containing component has a continuous matrix of fibers only [e.g., porous paper, etc.]
    • Y10T428/249964—Fibers of defined composition

Definitions

  • the present invention relates to composite PUR/PIR foam core products and methods and, in particular, the manufacturer of such foam core products having fiberglass exterior layers utilizing formulations that produce lightweight, strong sheets and methods of directly foaming or using adhesives for adhering a consolidated fiberglass web to the foam core.
  • PUR/PIR foams are well known in the art. The density of these products is typically 2.0 pounds per cubic foot. Such foam is often used for insulation. PUR/PIR foam is relatively lightweight, but is generally not used by itself as a structural building material. It is desirable to provide PUR/PIR foam products that are lightweight and strong enough to use in place of plywood, composition board or the like.
  • the invention provides composite PUR/PIR foam core products and methods for producing same. Specifically, a composite foam product having top and bottom layers of a fiberglass fiber web which are adhered to a foam core to provide strong lightweight sheets is disclosed.
  • the core foam preferably has a density of at least four pounds per cubic foot (64 kg/m 3 ) and tensile strength in the lamination direction of at least 30 psi (2.1 bar) stress at break.
  • the composite foam may be made by either foaming directly onto consolidated fiberglass webbing or using an adhesive to apply top and bottom sheets of such consolidated webbing to premade foam. Where direct foaming is performed, it is preferable to use an extruder to mix the PUR/PIR foaming materials which are directly deposited onto a bottom sheet of the consolidated fiberglass web and apply a top sheet of the web via use of a conventional oven laminator. Upon exit from the laminator, the product is cut into sheets.
  • the PUR/PIR foam is formed into sheets having upper and lower facing material using a conventional laminator such as disclosed in U.S. Pat. No. 4,795,763.
  • a perforator is employed to make holes into the foam sheet through the facer.
  • the foam is preferably then cut into standardized sheets and equivalent size sheets of consolidated fiberglass webs are glued to the facing sheets on the top and bottom of the foam core. The latter method produces less waste of the consolidated fiberglass web which is generally significantly more expensive than the foam and facer material.
  • the consolidated fiberglass sheet is preferably fiberglass as a web intermingled with polypropylene or polyester fibers such as fiberglass sold under the trademark TWINTEX®.
  • the fiberglass web is pre-treated using heat and pressure to consolidate the fibers into a relatively rigid sheet.
  • the consolidated web weighs between 22 to 44 ounces per square yard (750- 1490 g/m 2 ) and has a thickness between 0.5 and 1.0 millimeters.
  • a corona treatment may also be applied to the web through which the web is subject to an electric field of about 50 dynes, such as when polypropylene/fiberglass material is used. During the corona treatment, oxygen molecules within the discharge area break into their atomic form and are free to bond to the ends of the molecules in the material being treated, resulting in a chemically-activated surface.
  • the foam composite product produced by the invention may be commercially utilized to form panels. Such panels may be used in place of heavier wood pallets and/or plywood. Such panels produced are lighter and stronger than currently available panels, and have commercial applications including, but not limited to chicken cases, desks and tables, marine panels, entry doors, garage doors, shipping rack floors and bleachers.
  • FIG. 1 is a schematic illustration of a laminator system which can be used to manufacture a composite foam product in accordance with the present invention.
  • FIG. 2 is a schematic illustration of a preferred foam mixing system.
  • FIG. 3 is a table listing various physical properties of different embodiments of the present invention.
  • the composite foam of the present invention generally comprises upper and lower layers of a consolidated fiberglass web which are adhered to PUR/PIR foam core.
  • Relatively thin sheets of consolidated fiberglass material are used, preferably less than ⁇ fraction (1/8) ⁇ inches (3.2 mm) in thickness and having a weight of at least 10 ounces per square yard (340 g/m 2 ), preferably at least 20 ounces per square yard (680 g/cm 2 ).
  • a foam core which is sufficiently adhered to the fiberglass material layers, a rigid lightweight, strong sheet is produced.
  • the foam core has a relatively high density of approximately four (4) pounds per cubic foot (64 kg/m 3 ) or more.
  • the composite foam is preferably manufactured to have a thickness of ⁇ fraction (3/4) ⁇ inch to one inch (19 to 25 mm).
  • a TWINTEX® polypropylene/fiberglass web is pre-treated with heat and pressure to form a consolidated relatively rigid sheet.
  • the consolidated fiberglass web maybe as textile fiber glass commingled with either a polypropylene (PP) or polyester (PET) fiber.
  • the consolidated fiberglass web may be continuous filament fiberglass commingled with either a polypropylene (PP) or polyester (PET) fiber.
  • Such consolidated sheets are commercially available in various thicknesses such as 44 ounce per square foot material which is approximately 1 mm thick, and 22 ounce per square yard material which is approximately 0.5 mm thick. However, it is possible to use much thicker fiberglass webs.
  • a foam lamination system 10 there is shown a foam lamination system 10 .
  • a foam mixing system 100 is provided which mixes the foam ingredients which are introduced to the laminator system 10 .
  • the laminator is provided with a roll 30 of lower facing material 31 and a roll of 30 ′ of upper facing material 31 ′.
  • the laminator is also provided with metering rolls 32 , 33 , and an enclosed heating/cooling system wherein the foam is cured which includes heating section 34 a and cooling section 34 b . Hot and cold air, respectively, may be circulated through the respective heating 34 a and cooling 34 b sections by respective vents 35 a , 35 b .
  • the laminator also includes pull rolls 36 , 37 .
  • cutters are provided on both sides of the laminator.
  • the pull rolls 36 and 37 may have respective flexible outer sheaths 38 , 39 or can be configured with spikes to make perforations in the foam.
  • Outer sheaths 38 , 39 are preferably provided with spikes when a separate adhesion process is used to apply the consolidated fiberglass sheeting material where direct foaming onto the fiberglass sheeting material is performed, no perforations are made.
  • a separate perforator may be provided where needed.
  • One method for making the composite foam products is to supply the upper and lower layers of consolidated fiberglass web material from rolls 30 , 30 ′ as sheets 31 and 31 ′.
  • the PUR/PIR foam core material is deposited from mixing equipment 100 onto the bottom layer 31 of the consolidated fiberglass web directly and the upper and lower layers of fiberglass web material bond to the PUR/PIR foam as it passes through the heating and cooling sections 34 a , 34 b of the laminator 10 .
  • the laminated product is cut to size via cutters 40 a , 40 b .
  • inherent in this process is the side waste material produced by the side cutter 40 a . If during the manufacturing process some defect is uncovered in the foam, the entire panels may need to be discarded which results in scrapping not only the foam core, but the adhered relatively expensive fiberglass layers.
  • an alternate method is provided to make the composite product.
  • the core foam is foamed onto inexpensive facing sheets such as paper sheets which may contain a small amount of fiberglass fibers.
  • Top and bottom face sheets are applied as sheets 31 , 31 ′ of FIG. 1 and a perforator is provided such as by using spikes on sheaths 38 and 39 to form small holes in the foam.
  • Foam sheets 46 of a desired size having front and back facers are then further processed by applying correspondingly sized sheets of the consolidated fiberglass web material using an adhesive.
  • a polyurethane moisture cure thermoset adhesive such as ISO-SET 3030D, available from Ashland Specialty Chemical Company, a division of Ashland, Inc.
  • the perforations through the facer are between 1 ⁇ 8 and ⁇ fraction (1/16) ⁇ of an inch in diameter and between ⁇ fraction (1/2) ⁇ and ⁇ fraction (3/4) ⁇ of an inch deep.
  • a preferred foam mixing system in the form of an extruder system 102 comprising a twelve-barrel extruder 104 and a reservoir system 106 for introducing the various components into the extruder barrels C 1 -C 12 during the foam making process.
  • the extruder includes feed ports 150 and 152 where granular material and solids may be conveniently added and mixed in the screw of the extruder as explained in detail in U.S. Patent RE 37,095.
  • the reservoirs 151 , 153 , 154 , 155 and 156 are maintained on site with the extruder in the foam manufacturing area.
  • filler material such as glass fibers and/or microspheres may be provided to the extruder system 102 at barrels C 1 and C 4 from hoppers 150 and 152 .
  • a mixture of isocyanate and optionally surfactant is preferably fed to the extruder 104 at barrel C 2 from reservoir 151 .
  • An additional mixture of isocyanate and optionally surfactant may also be added to the extruder 104 at barrel C 6 from reservoir 153 .
  • a foaming agent such as isopentane, n-pentane, cyclopentane, other hydrocarbons, hydrochlorofluorocarbons (HCFC), hydrofluorocarbons (HFC) or any combination thereof is provided to the extruder 104 at barrel C 8 from reservoir 154 .
  • Polyol, a foaming agent, such as pentane, HCFC, or HFC, and surfactant are preferably fed to the extruder 104 at barrel C 9 from reservoir 155 .
  • water is utilized as the foaming/blowing agent precursor, it may be mixed with the polyol in reservoir 155 , thereby producing CO 2 when it mixes with the isocyanate. Alternatively, water and liquid CO 2 may be utilized.
  • a catalyst or catalyst mixture such as an amine and potassium octoate is provided to the extruder head 120 from reservoir 156 .
  • the extruded mixture of PUR/PIR foam ingredients exits the extruder head 120 and is deposited in the laminator 10 where it foams, firms and cures during the lamination process as discussed above in conjunction with FIG. 1 .
  • a preferred formulation for the PUR/PIR foam include the following ingredients identified as parts per weight: TABLE 1 Polyester or Polyether Polyol 408 Surfactant 8.2 Blowing Agent 6-45 Glass or Polymeric Microspheres 0-180 Catalyst 14.2 Isocyanate 400-650
  • Foam was made using the extruder and laminator using both the direct foaming method and the adhesion foaming method onto consolidated TWINTEX® polypropylene material having a thickness of approximately 1 millimeter and weight of approximately 44 ounces per square yard.
  • the foam was made by introducing isocyanate at barrels C 2 and C 6 of approximately 600 parts per weight of the foam materials.
  • a polyester polyol in the amount of about 408 parts per weight, a silicon based surfactant, available from Goldschmidt, in the amount of about 8.2 parts per weight, and additional blowing agent, HCFC 22 available from DuPont, in the amount of about 15 parts per weight were added to the other foam ingredients in barrel C 9 of the extruder 104 .
  • Catalysts in the form of potassium octoate in the amount of about 12.2 parts per weight and amine, preferably DABCO® TMR-30 available from Air Products and Chemicals, in the amount of about 2 parts per weight were added in the extruder head from which the mixed foam ingredients were extruded to produce the foam core material.
  • Example 1 the foam was extruded between facing sheets of polypropylene coated glass having a weight of approximately 8 ounces per square yard and formed into sheets of a pre-determined size. Thereafter ISO-SET 3030D polyurethane moisture cure thermoset adhesive was applied to both sides of the sheet to adhere upper and bottom layers of the consolidated TWINTEX® polypropylene web.
  • Example 2 In a second example, identified as Example 2, the same process was followed, but the facer sheets which were used were a 20 gauge black paper having small amounts of fiberglass available from GAF having a weight of approximately 5 ounces per square yard.
  • Example 3 A third example of composite product was made, identified as Example 3, referred to as “direct” wherein the foam materials were extruded directly between sheets of the consolidated TWINTEX® polypropylene web to produce the consolidated product through the laminator without any further adhesion processing. The tensile strength tests showed that the direct sample exhibited excellent adhesion strength.
  • the direct foam composite product proved to be an excellent replacement for wood, but lighter in weight.
  • Table 2 reflects compressive strength of two samples 3a, 3b of the composite foam made using the direct foam application method.
  • the consolidated sheets having a finished thickness of ⁇ fraction (3/4) ⁇ inches and a core density of approximately 4.5 pounds per cubic foot.
  • Example 4 A fourth example of the laminated product, identified as Example 4, was made using the same foam formulation and facer as used in sample 2, i.e. the black paper, but the number of perforations in the faced foam was increased and the amount of adhesive was increased in applying the TWINTEX® polypropylene web. This dramatically improved the adhesion.
  • Example 5 the foam was directly deposited onto the TWINTEX® polypropylene web on a cleaned web having corona treatment.
  • example 6 the foam was deposited on corona treated consolidated TWINTEX® polypropylene without any cleaning.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
US10/489,014 2001-09-12 2002-09-11 Composite foam products and method Abandoned US20050042436A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US10/489,014 US20050042436A1 (en) 2001-09-12 2002-09-11 Composite foam products and method
US11/786,921 US20070193677A1 (en) 2001-09-12 2007-04-11 Method for manufacturing composite foam products

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WO2011086478A1 (de) * 2010-01-15 2011-07-21 Sonderhoff Chemicals Gmbh Verfahren und vorrichtung zum herstellen von polymerkaschierungen oder strangförmigen aufträgen an einem substrat
US8691340B2 (en) 2008-12-31 2014-04-08 Apinee, Inc. Preservation of wood, compositions and methods thereof
US9878464B1 (en) 2011-06-30 2018-01-30 Apinee, Inc. Preservation of cellulosic materials, compositions and methods thereof
US20210381229A1 (en) * 2020-06-05 2021-12-09 Johns Manville Non-wicking underlayment board
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EP1790451A1 (en) * 2005-11-25 2007-05-30 Kingspan Research and Developments Limited Manufacturing a rigid polymeric insulating foam board
US20100092597A1 (en) * 2007-03-08 2010-04-15 Angelo Candiracci Process and device for producing blocks of material
US8894397B2 (en) * 2007-03-08 2014-11-25 Angelo Candiracci Process and device for producing blocks of material
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US20210381229A1 (en) * 2020-06-05 2021-12-09 Johns Manville Non-wicking underlayment board
US20210381259A1 (en) * 2020-06-05 2021-12-09 Johns Manville Non-wicking underlayment board
US11685140B2 (en) * 2020-06-05 2023-06-27 Johns Manville Non-wicking underlayment board
US11773586B2 (en) * 2020-06-05 2023-10-03 Johns Manville Non-wicking underlayment board

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US20070193677A1 (en) 2007-08-23
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WO2003022566A1 (en) 2003-03-20
CA2459990A1 (en) 2003-03-20
US7291234B2 (en) 2007-11-06

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