Composite board containing glass fiber mat

• US 20090110885A1
• Filed: 09/28/2007
• Published: 04/30/2009
• Est. Priority Date: 09/28/2007
• Status: Active Grant

• Current Assignee: Johns Manville Corporation (Berkshire Hathaway Incorporated)
• Original Assignee: Johns Manville Corporation (Berkshire Hathaway Incorporated)
• Inventors: Schweitzer, Mandy B., Paradis, Duane
• Granted Patent: US 8,546,278 B2
• Time in Patent Office: Days
• US Class Current: 428/160
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• 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 5/28 impregnated with or embedded in a plastic substance not used
• CPC Class Codes: E04B 1/625 Sheets or foils allowing passage of water vapor but impervious to liquid water; house wraps
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 428/24496 Foamed or cellular component
• CPC Class Codes: Y10T 428/24504 Component comprises a polymer [e.g., rubber, etc.]
• CPC Class Codes: Y10T 428/24512 Polyurethane
• CPC Class Codes: Y10T 442/176 Three or more layers
• CPC Class Codes: Y10T 442/2041 Two or more non-extruded coatings or impregnations
• CPC Class Codes: Y10T 442/2049 Each major face of the fabric has at least one coating or impregnation
• CPC Class Codes: Y10T 442/2057 At least two coatings or impregnations of different chemical composition
• CPC Class Codes: Y10T 442/2066 Different coatings or impregnations on opposite faces of the fabric
• CPC Class Codes: Y10T 442/2074 At least one coating or impregnation contains particulate material
• CPC Class Codes: Y10T 442/2992 Coated or impregnated glass fiber fabric

Abstract

A composite board including: at least one glass fiber mat having an upper surface and a lower surface; a foam layer attached to the glass fiber mat; and a first binding composition applied to the upper surface of the at least one glass fiber mat and a second binding composition applied to the lower surface of the at least one glass fiber mat, the first and second binding compositions being the same or different compositions.

Claims

1. A composite board comprising:

at least one glass fiber mat having an upper surface and a lower surface;

a foam layer attached to the glass fiber mat; and

a first binding composition applied to the upper surface of the at least one glass fiber mat and a second binding composition applied to the lower surface of the at least one glass fiber mat, the first and second binding compositions being the same or different compositions.

2. The composite board according to claim 1, wherein the at least one glass fiber mat comprises first and second glass fiber mats, the foam layer being arranged between the first and second glass fiber mats and attached to each of the first and second glass fiber mats.

3. The composite board according to claim 1, wherein the first binding composition penetrates into the glass fiber mat beyond the upper surface, and the second binding composition penetrates into the glass fiber mat beyond the lower surface.

4. The composite board according to claim 3, wherein the first and/or second binding compositions penetrates into the glass fiber mat in an amount of at least about 85%, based on the total thickness of the glass fiber mat.

5. The composite board according to claim 3, wherein the total penetration of the first and second binding compositions into the glass fiber mat is at least 85%, based on the total thickness of the glass fiber mat.

6. The composite board according to claim 3, wherein the glass fiber mat is substantially completely impregnated with the first and/or second binding compositions.

7. The composite board according to claim 1, wherein the foam layer comprises a thermosetting polymer foam.

8. The composite board according to claim 1, wherein the foam layer comprises polyisocyanurate foam.

9. The composite board according to claim 8, wherein the polyisocyanurate foam has a density of from about 1.5 pounds per cubic foot to about 25 pounds per cubic foot.

10. The composite board according to claim 1, wherein the foam layer has a thickness of from about 0.125 inch to about 6 inches.

11. The composite board according to claim 8, wherein the glass fiber mat has a thickness of from about 0.015 inch to about 0.05 inch.

12. The composite board according to claim 1, wherein each of the first and second binding compositions comprises a binder and an inorganic filler.

13. The composite board according to claim 12, wherein the binder comprises a latex.

14. The composite board according to claim 13, wherein the binder comprises a styrene butadiene rubber latex.

15. The composite board according to claim 13, wherein each of the first and second binding compositions further comprises a secondary organic binder.

16. The composite board according to claim 13, wherein each of the first and second binding compositions comprises from about 1% latex to about 15% latex, based on the respective weight of each binding composition.

17. The composite board according to claim 16, wherein each of the first and second binding compositions comprises from about 1% latex to about 5% latex, based on the respective weight of each binding composition.

18. The composite board according to claim 12, wherein the inorganic filler is selected from the group consisting of calcium carbonate, clay, talc, mica, perlite, hollow ceramic spheres and a combination thereof.

19. The composite board according to claim 1, wherein the at least one glass fiber mat has a weight of from about 50 grams per square meter to about 150 grams per square meter.

20. The composite board according to claim 1, wherein the at least one glass fiber mat has a coat weight of from about 350 grams per square meter to about 800 grams per square meter.

21. The composite board according to claim 1, wherein the air permeability of the at least one glass fiber mat on which the first and second compositions have been applied, is such that it takes at least 300 seconds for 300 cubic centimeters of air to pass through 1 square inch of the glass fiber mat.

22. A method of making a composite board comprising:

applying a first binding composition to an upper surface of at least one glass fiber mat;

applying a second binding composition to a lower surface of the at least one glass fiber mat, wherein the first and second binding compositions are the same or different compositions; and

attaching a foam layer to the at least one glass fiber mat.

23. The method of making a composite board according to claim 22, further comprising applying the first and second binding compositions with first and second applicator roll.

24. The method of making a composite board according to claim 22, further comprising applying the first and second binding compositions to the at least one glass fiber mat with a plurality of spray nozzles.

25. The method of making a composite board according to claim 22, further comprising:

feeding the at least one glass fiber mat along a process line;

injecting a thermosetting polymer foam on the upper surface of the glass fiber mat;

applying heat to the thermosetting polymer foam until the thermosetting polymer foam rises, cures, and attaches to the upper surface of the glass fiber mat.