Construction boards with coated inorganic facer

• US 10,000,922 B1
• Filed: 12/30/2014
• Issued: 06/19/2018
• Est. Priority Date: 03/24/2011
• Status: Active Grant

• Current Assignee: Holcim Technology, Ltd. (Holcim Limited)
• Original Assignee: Firestone Building Products Company LLC (Bridgestone Corporation)
• Inventors: Letts, John
• Primary Examiner(s): Chriss, Jennifer
• Assistant Examiner(s): Ferguson, Lawrence
• Application Number:
  US14/585,637
• Time in Patent Office: 1,267 Days
• Field of Search: 428212, 428220, 428140, 4283188
• CPC Class Codes: B29C 44/326 Joining the preformed parts, e.g. to make flat or profiled sandwich laminates
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/0005 containing compounding ingredients releasing, lubricating or separating agents B29C33/56, fibers B29K2105/08, B29K2105/12; fillers B29K2105/16, recycled material B29K2105/26
• CPC Class Codes: B29K 2105/046 with closed cells
• CPC Class Codes: B29K 2105/128 in the form of a mat
• CPC Class Codes: B29K 2995/0016 Non-flammable or resistant to heat
• CPC Class Codes: B29K 2995/0063 Density
• CPC Class Codes: B29L 2031/776 Walls, e.g. building panels
• CPC Class Codes: B32B 11/10 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 11/12 next to a particulate layer
• CPC Class Codes: B32B 2037/243 Coating
• CPC Class Codes: B32B 2038/0084 Foaming
• CPC Class Codes: B32B 2255/02 on fibrous or filamentary layer
• CPC Class Codes: B32B 2255/10 on synthetic resin layer or on natural or synthetic rubber layer
• CPC Class Codes: B32B 2255/20 Inorganic coating
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2255/28 Multiple coating on one surface
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/025 Particulate layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/101 : Glass fibres
• CPC Class Codes: B32B 2307/3065 : Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/71 : Resistive to light or to UV
• CPC Class Codes: B32B 2307/718 : Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2307/72 : Density
• CPC Class Codes: B32B 2307/724 : Permeability to gases, adsorption
• CPC Class Codes: B32B 2307/732 : Dimensional properties
• CPC Class Codes: B32B 2419/06 : Roofs, roof membranes
• CPC Class Codes: B32B 25/047 : of particles
• CPC Class Codes: B32B 25/10 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 25/16 : comprising polydienes homopolymers or poly-halodienes homopolymers B32B25/12 takes precedence
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/14 : next to a particulate layer
• CPC Class Codes: B32B 27/304 : comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 3/26 : characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205; characterised by an apertured layer
• CPC Class Codes: B32B 37/24 : with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate B32B37/15 takes precedence
• CPC Class Codes: B32B 5/00 : 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
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/16 : characterised by features of a layer formed of particles, e.g. chips, powder or granules layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 5/30 : one layer being formed of particles, e.g. chips, granules, powder
• CPC Class Codes: B32B 7/022 : Mechanical properties
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: E04B 1/7658 : comprising fiber insulation, e.g. as panels or loose filled fibres
• CPC Class Codes: E04C 2/205 : of foamed plastics, or of plastics and foamed plastics, optionally reinforced
• CPC Class Codes: E04C 2/243 : one at least of the material being insulating
• CPC Class Codes: E04C 2/246 : combinations of materials fully covered by E04C2/16 and E04C2/20
• CPC Class Codes: E04D 13/16 : Insulating devices or arrangements in so far as the roof covering is concerned, e.g. characterised by the material or composition of the roof insulating material or its integration in the roof structure

Abstract

A construction board comprising (a) a foam core having a first planar surface and a second planar surface; (b) a facer, having first and second planar surfaces, including an inorganic fabric and a coating; and (c) an interfacial region between the foam core and said facer.

Claims

1. A construction board comprising:

(a) a foam core including a first planar surface and a second planar surface, where the foam core includes a polyurethane or polyisocyanurate cellular structure having a density that is less than 2.5 lbs/ft²;

(b) a first interfacial region including a particulate filler and a polymeric binder, said first interfacial region being disposed on said first planar surface of said foam core;

(c) a first non-woven inorganic mat disposed on said first interfacial region opposite said foam core;

(d) a second interfacial region including a particulate filler and a polymeric binder, said second interfacial region being disposed on said second planar surface of said foam core;

(e) a second non-woven inorganic mat disposed on said second interfacial region opposite said foam core;

(f) a first coating layer, including a particulate filler and a polymeric binder, disposed on said first non-woven inorganic mat on a planar surface opposite said first interfacial region; and

(g) a second coating layer, including a particulate filler and a polymeric binder layer, disposed on said second non-woven inorganic mat on a planar surface thereof opposite said second interfacial region.

2. The foam laminate of claim 1, where the non-woven inorganic mat is a non-woven fiberglass mat.

3. The foam laminate of claim 2, where the non-woven fiberglass mat includes a binder that binds the glass fibers together.

4. The foam laminate of claim 3, where the binder that binds the glass fibers together is a thermosetting resin.

5. The foam laminate of claim 4, where said non-woven fiberglass mat has a basis weight of from 50 to 150 g/m².

6. The foam laminate of claim 5, where the non-woven fiberglass mat has a thickness of 0.015 to 0.05 in.

7. The foam laminate of claim 1, where the polymeric binder binds the particulate filler together and binds the particulate filler to the non-woven inorganic mat.

8. The foam laminate of claim 7, where the polymeric binder is a latex or a starch.

9. The foam laminate of claim 1, where the particulate filler is selected from the group consisting of limestone, calcium carbonate, clay, talc, mica, perlite, hollow ceramic spheres, and combinations thereof.

10. The foam laminate of claim 1, where the polymeric binder at least partially penetrates the non-woven inorganic mat.

11. The foam laminate of claim 1, where said non-woven mat, together with the first interfacial region and the coating layer disposed thereon, is characterized by a porosity, as determined by ARC-WT-006, of less than 300 Gurley seconds/300 cm³.

12. The foam laminate of claim 1, where said non-woven mat, together with the second interfacial region and the coating layer disposed thereon, is characterized by a porosity, as determined by ARC-WT-006, of less than 100 Gurley seconds/300 cm³.

13. The foam laminate of claim 1, wherein said first interfacial region and said coating layer disposed on said first organic facer at least partially penetrate the first fabric substrate.

14. The foam laminate of claim 13, wherein the first interfacial region and said coating layer disposed on said first fabric substrate are characterized by a coating weight of greater than 500 g/m².

15. The foam laminate of claim 14, wherein the first interfacial region and said coating layer disposed on said first fabric substrate are characterized by a coating weight of greater than 850 g/m².

16. A construction board comprising

(a) a first facer having a first planar surface and a second planar surface, wherein the first facer includes a first fabric substrate having first and second planar surfaces, and where the first fabric is coated on both said first and second planar surfaces to provide coating layers disposed on said first and second planar surfaces of said first facer;

(b) a foam core having a first planar surface and a second planar surface, where the foam core includes a closed cell polyurethane or polyisocyanurate cellular structure having a density that is less than 2.5 pounds per cubic foot; and

(c) a second facer having a first planar surface, wherein the second facer includes a second facer substrate having first and second planar surfaces, and where the second fabric is coated on both said first and second planar surfaces to provide coating layers disposed on said first and second planar surfaces of said second facer, where said foam core is attached to the coating layer disposed on said second planar surface of said first facer and where said foam core is attached to the coating layer disposed on said first planar surface of said second facer.

17. A construction board comprising

(a) a foam core including a first planar surface and a second planar surface, where the foam core includes a polyurethane or polyisocyanurate cellular structure having a density that is less than 2.5 pounds per cubic foot;

(b) a first non-woven inorganic mat disposed adjacent to said first planar surface of said foam core;

(c) a first coating including a particulate filler and a polymeric binder, said first coating positioned between said foam core and said first non-woven inorganic mat;

(d) a second non-woven inorganic mat disposed adjacent to said second planar surface of said foam core;

(e) a second coating including a particulate filler and a polymeric binder, said second coating positioned between said foam core and said second non-woven inorganic mat;

(f) a third coating layer, including a particulate filler and a polymeric binder, disposed on said first non-woven inorganic mat on a planar surface opposite said first coating; and

(g) a fourth coating layer, including a particulate filler and a polymeric binder layer, disposed on said second non-woven inorganic mat on a planar surface thereof opposite said second coating.