Construction boards with coated inorganic facer

• US 10,450,741 B2
• Filed: 05/21/2018
• Issued: 10/22/2019
• 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): Ferguson, Lawrence D
• Application Number:
  US15/984,972
• Publication Number:
  US 20180320366A1
• Time in Patent Office: 519 Days
• 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:

(i) a foam core having first and second planar surfaces, where the foam core includes a polyisocyanurate cellular structure having an index of at least 175 and being formed by contacting an A-side stream of reactants including an isocyanate compound and a B-side stream of reactants including an isocyanate-reactive compound;

(ii) an interfacial region including a filler dispersed within a matrix, said interfacial region being disposed on said first planar surface of said foam core; and

(iii) a non-woven inorganic mat disposed on said interfacial region opposite said foam such that said core and said mat sandwich said interfacial region.

2. The construction board of claim 1, where said construction board further comprises a coating layer disposed on said non-woven inorganic mat opposite said interfacial region.

3. The construction board of claim 2, where said coating layer includes filler dispersed within a matrix.

4. The construction board of claim 3, where said filler includes an inorganic filler.

5. The construction board of claim 4, where said inorganic filler is selected from the group consisting of limestone, calcium carbonate, clay, talc, mica, perlite, hollow ceramic spheres, and combinations thereof.

6. The construction board of claim 5, where said coating includes at least 80% by weight filler and from about 1 to about 15% by weight matrix.

7. The construction board of claim 6, where said matrix is a polymeric binder.

8. The construction board of claim 1, where said filler within said interfacial region is an inorganic filler.

9. The construction board of claim 8, where said inorganic filler is selected from the group consisting of limestone, calcium carbonate, clay, talc, mica, perlite, hollow ceramic spheres, and combinations thereof.

10. The construction board of claim 8, where said matrix of said interfacial region is a polymeric binder.

11. The construction board of claim 8, where said interfacial region includes at least 80% by weight filler and from about 1 to about 15% by weight matrix.

12. The construction board of claim 1, where said construction board further comprises a second interfacial region including a filler dispersed within a matrix;

said second interfacial region being disposed on said second planar surface of said foam core.

13. The construction board of claim 12, where said construction board further comprises a second non-woven inorganic mat disposed on said second interfacial region opposite said foam core so that said foam core and second non-woven mat sandwich said second interfacial region.

14. A construction board comprising:

(i) a foam layer, said foam layer including polyisocyanurate and having first and second planar surfaces;

(ii) a coating layer having first and second planar surfaces, where said first planar surface of said coating is mated to said first planar surface of said foam layer, said coating layer including an inorganic filler dispersed within a polymeric matrix; and

(iii) a non-woven mat having first and second planar surfaces, where said first planar surface of said non-woven mat is mated to said second planar surface of said coating layer.

15. The construction board of claim 14, where said construction board further comprises a second coating layer having first and second planar surfaces, where said first planar surface of said second coating layer is mated to said second planar surface of said non-woven mat, and where said second coating layer includes an inorganic filler dispersed within a polymeric matrix.

16. A construction board prepared by a process comprising:

(i) providing a non-woven mat having a coating layer disposed on a planar surface thereof, where the coating layer includes an inorganic filler dispersed within a polymeric matrix;

(ii) contacting an A-side stream of reactants including an isocyanate compound with a B-side stream of reactants including an isocyanate-reactive compound to prepare a developing foam; and

(iii) depositing the developing foam on to said coating of said non-woven mat.

17. The construction board of claim 16, further comprising the step of heating the developing foam within a laminator.

18. The construction board of claim 17, where after said step of depositing the developing foam on to said coating and prior to heating the developing foam, mating said developing foam to a facer.

19. The construction board of claim 18, where said facer includes a coating layer disposed on a planar surface thereof, where the coating includes an inorganic filler dispersed within a polymeric matrix.