Composite building panel

• US 4,459,334 A
• Filed: 08/17/1982
• Issued: 07/10/1984
• Est. Priority Date: 10/08/1981
• Status: Expired due to Term

• Current Assignee: RMAX Incorporated
• Original Assignee: RMAX Incorporated
• Inventors: Blanpied, Robert H., Odland, Russell K., Vaden, Walter Z.
• Primary Examiner(s): VAN BALEN, WILLIAM
• Application Number:
  US06/408,939
• Time in Patent Office: 693 Days
• Field of Search: 428/317.5, 428/319.1, 428/422.8, 428/304.4, 428/219, 428/220, 428/285, 521/118, 521/128, 521/172, 156/79
• US Class Current: 428/219
• CPC Class Codes: B29C 44/129 Enhancing adhesion to the preformed part using an interlayer
• CPC Class Codes: B32B 15/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 15/20 comprising aluminium or copper B32B15/016 and B32B15/017 take precedence
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2266/02 Organic
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/3065 Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/245 another layer next to it being a foam layer
• CPC Class Codes: C08G 18/4018 Mixtures of compounds of group C08G18/42 with compounds of group C08G18/48
• CPC Class Codes: C08G 2110/0025 rigid
• CPC Class Codes: C08G 2170/60 Compositions for foaming; Foamed or intumescent adhesives
• CPC Class Codes: E04C 2/292 composed of insulating material and sheet metal
• CPC Class Codes: E04C 2/296 composed of insulating material and non-metallic or unspecified sheet-material E04C2/288 takes precedence
• CPC Class Codes: Y10T 428/249984 Adhesive or bonding component contains voids
• CPC Class Codes: Y10T 428/24999 Inorganic
• CPC Class Codes: Y10T 428/31547 Of polyisocyanurate
• CPC Class Codes: Y10T 442/648 Including a free metal or alloy constituent
• CPC Class Codes: Y10T 442/656 Preformed metallic film or foil or sheet [film or foil or sheet had structural integrity prior to association with the nonwoven fabric]

Abstract

A composite panel for use in the construction industry includes a core of foamed plastic material and a skin on at least one of its faces comprised of a two-ply material consisting of aluminum foil bonded to a mat of randomly oriented glass fibers into which the foam core has been expanded.

The core material comprises the rection product of isocyanurate and polyester/polyether polyol with the isocyanurate in sufficient excess to form trimmer rings and to react with the polyol to form urethane linkages.

Panels formed of the core material and the two-ply skins have excellent thermal insulation and fire retardant properties and the skins have excellent mechanical strength.

Claims

1. A composite building panel comprising:

a core of rigid foamed plastic material;

protective facing material secured to the front and back surfaces of said core;

wherein said foamed core comprises the catalyzed reaction product of isocyanate and a blended polyester/polyether polyol which comprises between about 40%-60% dimethylterephthalate/glycol based polyester polyol mixed with between about 60%-40% alkyloxylated sucrose, or sucrose-amine, based polyether polyol wherein the isocyanate is in sufficient excess to form isocyanurate (trimer) rings and also to react with the polyester/polyether polyol to form urethane linkages.

2. A composite building panel as claimed in claim 1 wherein the foam core has an isocyanate- to hydroxyl-group ratio of between about 1.8:

1 and 6.0 to 0;

1.

3. A composite building panel as claimed in claim 1 wherein at least one of said protective facing materials includes a skin comprising an outer layer of aluminum foil of approximately 0.0003 inch to 0.0008 inch thickness, backed by and bonded to a mat of randomly oriented glass fibers, said mat being penetrated by said foam to adhere said skin to said core.

4. A composite building panel, according to claim 3, wherein the mat comprises glass fibers in the range of 6 to 16 microns in diameter and between about 1/4 of an inch and 11/2 inch in nominal length.

5. A composite panel, according to claim 4, wherein the mat comprises between about four and thirty pounds of glass fiber per 1,000 square foot of mat.

6. A method of forming a foam core for a composite building panel comprising:

providing a polyisocyanate component and a polyol component, said polyol component comprising between 40%-60% dimethylterephthalate/glycol based polyester polyol mixed with between about 60%-40% alkyloxylated sucrose, or sucrose-amine, based polyether polyol;

a catalyst, mixture having the catalytic properties of both an organic salt and a tertiary amine;

a fluorocarbon blowing agent, and

a surfactant mixing the polyisocyante component and the polyol component in proportion between about 1;

1 and 2;

1 and forming therefrom a foam reaction product resulting from trimerization of the polyisocyanate plus the reaction of the polyisocyanate with the polyol to form urethane linkages.