Structural laminates made with novel facing sheets

• US 5,001,005 A
• Filed: 08/17/1990
• Issued: 03/19/1991
• Est. Priority Date: 08/17/1990
• Status: Expired due to Term

• Current Assignee: Atlas Roofing Corporation (Hood Cos., Inc.)
• Original Assignee: Atlas Roofing Corporation (Hood Cos., Inc.)
• Inventors: Blanpied, Robert H.
• Primary Examiner(s): VAN BALEN, WILLIAM
• Application Number:
  US07/568,705
• Time in Patent Office: 214 Days
• Field of Search: 428/283, 428/285, 428/304.4, 428/319.1, 428/323, 428/324, 428/326, 428/328
• US Class Current: 442/373
• CPC Class Codes: B29C 67/248 Moulding mineral fibres or particles bonded with resin, e.g. for insulating or roofing board articles from wood or lignocellulosic material with binding agents B27N; mineral aggregates bonded with resin B29C67/242; thermal insulation in general F16L59/00
• CPC Class Codes: B29C 70/00 Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
• CPC Class Codes: B29K 2309/08 Glass
• CPC Class Codes: B32B 17/04 bonded with or embedded in a plastic substance
• CPC Class Codes: B32B 17/066 of foam
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2315/085 Glass fiber cloth or fabric
• CPC Class Codes: B32B 2315/10 Mica
• CPC Class Codes: B32B 2315/16 Clay
• CPC Class Codes: B32B 2398/10 Thermosetting resins
• CPC Class Codes: B32B 27/20 using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 5/245 another layer next to it being a foam layer
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/24999 Inorganic
• CPC Class Codes: Y10T 428/25 Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/251 Mica
• CPC Class Codes: Y10T 428/253 Cellulosic [e.g., wood, paper, cork, rayon, etc.]
• CPC Class Codes: Y10T 428/256 Heavy metal or aluminum or compound thereof
• CPC Class Codes: Y10T 442/651 Plural fabric layers
• CPC Class Codes: Y10T 442/699 Including particulate material other than strand or fiber material

Abstract

A structural laminate comprises at least one planar facing sheet comprised largely of glass fibers but not having micro-glass as a filler. The facing sheet is self adhered to a rigid thermosetting plastic foam core. The non-glass filler material is chosen from a group consisting of clay, mica, talc, limestone (calcium carbonate), gypsum (calcium sulfate), aluminum trihydrate (ATH), antimony oxide, cellulose fibers, and plastic polymer fibers. The non-glass filler material improves containment of liquid plastic thermosetting polymer, and offers economic and safety advantages.

Claims

1. A thermosetting plastic foam laminate comprising:

(1) at least one planar facing sheet comprising;

(A) from 60% to 90% by weight glass fibers exclusive of glass micro-fibers, and

(B) from 10% to 40% by weight non-glass filler material, and

(C) from 1% to 30% by weight non-asphaltic binder material which bonds the fibers together and bonds the filler materials to the fibers;

(2) a rigid foam integrally attached upon formation of the foam to the surface of a facing sheet, the rigid foam formed from a thermosetting catalyzed plastic reaction product capable of being foamed.

2. The thermosetting plastic foam laminate of claim 1 wherein there are two parallel facing sheets of the same composition.

3. The thermosetting plastic foam laminate of claim 1 wherein said non-glass filler material is chosen from a group consisting of clay, mica, talc, limestone (calcium carbonate), gypsum (calcium sulfate), aluminum trihydrate (ATH), antimony oxide, cellulose fibers, and plastic polymer fibers.

4. A method of making a thermosetting plastic foam laminate, said method comprising:

binding a non-glass filler material to a mat of glass fibers which does not contain glass micro-fibers to form a planar facing sheet, whereby said planar facing sheet comprises from 60% to 90% by weight glass fibers and from 10% to 40% by weight non-glass filler material;

attaching a rigid foam formed from a thermosetting catalyzed plastic reaction product capable of being foamed to said planar facing sheet upon formation of the foam.

5. The method of claim 4, wherein two parallel facing sheets of the same composition are attached to said rigid foam.

6. The method of 4, wherein said non-glass filler material is chosen from a group consisting of clay, mica, talc, limestone (calcium carbonate), gypsum (calcium sulfate), aluminum trihydrate (ATH), antimony oxide, cellulose fibers, and plastic polymer fibers.

7. The method of claim 6, wherein said binding is accomplished using from 1% to 30% by weight non-asphaltic binder material which bonds the fibers together and bonds the filler materials to the fibers.