Tough and durable insulation boards produced in-part with scrap rubber materials and related methods

• US 20030082365A1
• Filed: 10/30/2001
• Published: 05/01/2003
• Est. Priority Date: 10/30/2001
• Status: Abandoned Application

• Current Assignee: BFS Diversified Products LLC (Bridgestone Corporation)
• Original Assignee: BFS Diversified Products LLC (Bridgestone Corporation)
• Inventors: Brandt, Greg A., OʼConnor, Terence J., Letts, John B., Douglas, Bruce F., Geary, John R.
• Application Number:
  US10/020,826
• Publication Number:
  US 20030082365A1
• Time in Patent Office: Days
• US Class Current: 428/318.4
• CPC Class Codes: B29C 44/326 Joining the preformed parts, e.g. to make flat or profiled sandwich laminates
• CPC Class Codes: B32B 2038/0076 Curing, vulcanising, cross-linking
• CPC Class Codes: B32B 2038/0084 Foaming
• CPC Class Codes: B32B 2305/70 Scrap or recycled material
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 27/20 using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 37/20 involving the assembly of continuous webs only
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: E04C 2/296 composed of insulating material and non-metallic or unspecified sheet-material E04C2/288 takes precedence
• CPC Class Codes: E04D 11/02 Build-up roofs, i.e. consisting of two or more layers bonded together in situ, at least one of the layers being of watertight composition gravelling of flat roofs E04D7/00; venting or ventilation E04D13/17
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249958 Void-containing component is synthetic resin or natural rubbers
• CPC Class Codes: Y10T 428/249967 Inorganic matrix in void-containing component
• CPC Class Codes: Y10T 428/249969 Of silicon-containing material [e.g., glass, etc.]
• CPC Class Codes: Y10T 428/24997 Of metal-containing material
• CPC Class Codes: Y10T 428/249986 Void-containing component contains also a solid fiber or solid particle
• CPC Class Codes: Y10T 428/249987 With nonvoid component of specified composition
• CPC Class Codes: Y10T 428/249999 Differentially filled foam, filled plural layers, or filled layer with coat of filling material

Abstract

A composite recovery board (10, 20, 30) comprises a foam core (11) having lower (12) and upper (13) surfaces, wherein the foam core is selected from the group consisting of polyisocyanurate and polyurethane materials and mixtures thereof; and a filler within said foam core selected from the group consisting of rubber-tire vents, EPDM scrap material, plastic chips, polyurethane scrap, polyisocyanurate scrap, scrap rubber from recycled tires, wood chips, fiberglass strands and mixtures thereof. A method of re-roofing a roof comprising applying composite boards (10, 20, 30) of the present invention to a roof deck and applying a weather protective layer over the composite boards. A continuous method of making composite recovery boards (10) of the present invention comprises is also provided.

Claims

1. A composite board comprising:

a foam core having upper and lower surfaces, wherein said foam core is selected from the group consisting of polyisocyanurate and polyurethane and mixtures thereof; and

a filler material within said foam core selected from the group consisting of rubber-tire vents, EPDM scrap material, plastic chips, polyurethane scrap, polyisocyanurate scrap, scrap rubber from recycled tires, wood chips, fiberglass strands and mixtures thereof.

2. A composite board, as set forth in claim 1, wherein said foam core comprises polyisocyanurate having an iso index above 200.

3. A composite board as set forth in claim 1, further comprising a facer material applied to one of said surfaces of said filled foam core.

4. A composite board as set forth in claim 3, wherein said facer material is selected from the group consisting of polymer materials, reinforced polymer materials, reinforced cellulosic material, paper, aluminum foil and trilaminates thereof.

5. A composite board, as set forth in claim 4, wherein a facer material is applied to said other surface of said filled foam core.

6. A composite board, as set forth in claim 5, wherein a substrate material is applied to said lower surface of said filled foam core in lieu of said facer material.

7. A composite board, as set forth in claim 1, wherein a substrate material is applied to one of said surfaces of said filled foam core.

8. A method of re-roofing a roof comprising:

applying composite recovery boards to a roof deck, said recovery boards comprising

a foam core having upper and lower surfaces, wherein said foam core is selected from the group consisting of polyisocyanurate and polyurethane and mixtures thereof; and

filler material within said foam core selected from the group consisting of rubber-tire vents, EPDM scrap material, plastic chips, polyurethane scrap, polyisocyanurate scrap, scrap rubber from recycled tires, wood chips, fiberglass strands and mixtures thereof; and

applying a weather protective layer over said recovery boards.

9. A method of re-roofing a roof, as set forth in claim 8, further comprising the step of applying a facer material to one of said surfaces of said filled foam core.

10. A method of re-roofing a roof, as set forth in claim 9, wherein said facer material is selected from the group consisting of polymer materials, reinforced polymer materials, reinforced cellulosic material, paper, aluminum foil and trilaminates thereof.

11. A method of re-roofing a roof, as set forth in claim 10, including the step of applying a second facer material to said other surface of said filled foam core.

12. A method of re-roofing a roof, as set forth in claim 8, including the step of applying a substrate material to said lower surface of said filled foam core in lieu of said facer material.

13. A method of re-roofing a roof, as set forth in claim 8, wherein a substrate material is applied to one of said surfaces of said filled foam core.

14. A continuous method of making a composite board comprising the steps of:

feeding a first sheet of facer material into a conveyor assembly;

depositing a filled foamable polymer liquid onto said facer;

feeding a second facer material into the conveyor assembly above the filled foamable polymer liquid;

allowing said filled foamable polymer liquid to rise between said facer materials in order to form filled polymer foam of a predetermined thickness;

curing said polymer foam under heat to create the composite board; and

cutting the composite board to desired lengths.

15. A continuous method, as set forth in claim 14, wherein said recovery boards comprise

a foam core having upper and lower surfaces, wherein said foam core is selected from the group consisting of polyisocyanurate and polyurethane and mixtures thereof;

and

filler material within said foam core selected from the group consisting of rubber-tire vents, EPDM scrap material, plastic chips, polyurethane scrap, polyisocyanurate scrap, scrap rubber from recycled tires, wood chips, fiberglass strands and mixtures thereof.

16. A continuous, as set forth in claim 14, wherein said recovery board further comprising a facer material applied to one of said surfaces of said filled foam core.

17. A continuous, as set forth in claim 16, wherein said facer material is selected from the group consisting of polymer materials, reinforced polymer materials, reinforced cellulosic material, paper, aluminum foil and trilaminates thereof.

18. A continuous, as set forth in claim 14, wherein said recovery board further comprises a second facer material is applied to said other surface of said filled foam core.

19. A continuous, as set forth in claim 18, wherein a substrate material is applied to said lower surface of said filled foam core in lieu of said facer material.

20. A composite board, as set forth in claim 14, wherein a substrate material is applied to one of said surfaces of said filled foam core.