Polyisocyanurate boards with reduced moisture absorbency and lower air permeability and related methods

• US 5,891,563 A
• Filed: 10/08/1996
• Issued: 04/06/1999
• Est. Priority Date: 10/08/1996
• Status: Expired due to Term

• Current Assignee: Firestone Building Products Company LLC (Bridgestone Corporation)
• Original Assignee: Bridgestone Firestone North American Tire LLC (Bridgestone Corporation)
• Inventors: Letts, John B.
• Primary Examiner(s): WEISBERGER, RICHARD C
• Application Number:
  US08/727,812
• Time in Patent Office: 910 Days
• Field of Search: 428/140, 428/139, 428/304.4, 428/317.9, 428/306.6, 428/307.3, 428/318.4, 428/318.8, 156/71
• 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 2262/101 Glass fibres
• CPC Class Codes: B32B 2309/105 Thickness
• CPC Class Codes: B32B 2419/06 Roofs, roof membranes
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 27/20 using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 27/34 comprising polyamides
• CPC Class Codes: B32B 27/365 comprising polycarbonates
• 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 3/352 at least one insulating layer being located between non-insulating layers, e.g. double skin slabs or sheets
• CPC Class Codes: Y10T 428/24347 From both sides
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249955 Void-containing component partially impregnated with adjacent component
• CPC Class Codes: Y10T 428/249956 Void-containing component is inorganic
• 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 428/249989 Integrally formed skin

Abstract

A composite iso board (10) comprises a foam core (11) selected from the group consisting of polyisocyanurate and polyurethane materials and mixtures thereof; and first and second facers (12, 13), between which the foam core is sandwiched, the facers comprising a sheet selected from the group consisting of polyamides and polycarbonates. A method of reroofing a roof comprises applying composite iso boards of the present invention to a roof deck; and, applying a weather protective layer over the iso boards. A continuous method of making a composite iso board comprising the steps of feeding a first layer of facer material into a laminator (24); depositing a foamable polymer liquid onto the first layer (12); feeding a second layer of facer material (13) into the laminator above the foamable polymer liquid; allowing the polymer liquid to rise between the first and second facer materials forming polymer foam (42) of a predetermined thickness; curing the polymer foam under heat to create the iso board; cutting the iso board to desired lengths; and stacking said boards in bundles.

Claims

1. A composite iso recovery board comprising:

a foam core selected from the group consisting of polyisocyanurate and polyurethane materials and mixtures thereof; and

first and second facers, between which said foam core is sandwiched, said facers comprising a polymer sheet selected from the group consisting of polyamides and polycarbonates.

2. A composite iso board, as set forth in claim 1, wherein said facers further contain a reinforcing material selected from the group consisting of glass strands, glass fibers, and mixtures thereof.

3. A composite iso board, as set forth in claim 1, wherein said polyamides are selected from the group consisting of polyamide 6,6, polyamide 6, polyamide 11, polyamide 12 and polyamide 6,10.

4. A composite iso board, as set forth in claim 1, wherein said polymer sheets optionally contain a filler selected from the group consisting of clay, mica, talc, limestone, gypsum, aluminum trihydrate, antimony oxide, cellulose fibers, plastic polymer fibers, and mixtures thereof.

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

6. A composite iso board, as set forth in claim 1, wherein said foam core comprises polyurethane having an index above 120.

7. A composite iso board, as set forth in claim 1, wherein said facer has a thickness in the range from about 0.0005 to about 0.05 inches.

8. A composite iso board, as set forth in claim 2, wherein said facer comprises said reinforcing material in an amount from about 100 to about 10,000 parts by weight, based upon 100 parts by weight of the polymer selected to form the facer.

9. A composite iso board, as set forth in claim 1, wherein said polycarbonate is poly(4,4-isopropylidene diphenylene carbonate).

10. A composite iso board, as set forth in claim 1, wherein said facers further contain colorants.