Foamed facer and insulation boards made therefrom

• US 6,774,071 B2
• Filed: 04/08/2002
• Issued: 08/10/2004
• Est. Priority Date: 09/08/1998
• Status: Expired due to Term

• Current Assignee: Building Materials Investment Corporation (Standard Industries, Inc.)
• Original Assignee: Building Materials Investment Corporation (Standard Industries, Inc.)
• Inventors: Longcor, William K. IV, Horner, Charles J. Jr., Lichten, Lorin J.
• Primary Examiner(s): Zirker, Daniel
• Assistant Examiner(s): Chang, Victor S
• Application Number:
  US10/117,912
• Publication Number:
  US 20030032351A1
• Time in Patent Office: 855 Days
• Field of Search: 442/374, 442/76, 442/77, 442/136, 442/373
• US Class Current: 442/374
• CPC Class Codes: D04H 1/4218 Glass fibres
• CPC Class Codes: D04H 1/68 the bonding agent being applied in the form of foam
• CPC Class Codes: E04B 1/80 slab-shaped
• CPC Class Codes: Y10T 442/2139 Coating or impregnation specified as porous or permeable to a specific substance [e.g., water vapor, air, etc.]
• CPC Class Codes: Y10T 442/2148 Coating or impregnation is specified as microporous but is not a foam
• CPC Class Codes: Y10T 442/2631 Coating or impregnation provides heat or fire protection
• CPC Class Codes: Y10T 442/651 Plural fabric layers
• CPC Class Codes: Y10T 442/652 Nonwoven fabric is coated, impregnated, or autogenously bonded

Abstract

This invention relates to a low fiber, plyable facer suitable for use in the construction industry, particularly for insulation board manufacture, comprising a dry preformed fiber mat containing a binder for the fibers, preferably a preformed glass mat, coated with a prefoamed composition which contains a polymer latex, a foam sustaining amount of a surfactant and a flame retarding and/or strengthening amount of a mineral filler and also to the use and process for the preparation of the above as well as to a siding underlayment or insulation board having a foamed, thermosetting resin core which is surfaced with said facer as a product for commercial use.

Claims

1. A dry flexible facer comprising a non-asphaltic, non-cellulosic fiber mat surfaced with a cured foam comprising

(a) between about 15 and about 80 wt. % of a polymer latex,

(b) between about 0.01 and about 80 wt. % of a mineral filler and

(c) between about 0.5 and about 10 wt. % of a foam supporting surfactant, and

(d) between about 0.01 and about 5 wt. % of a catalyst.

2. The facer of claim 1 wherein said catalyst is selected from the group consisting of diammonium phosphate, para-toluene sulfonic acid, ammonium chloride and oxalic acid.

3. The facer of claim 1 wherein said surfactant is an ammonium salt of a C₁₀ to C₂₂ fatty acid.

4. The facer of claim 3 wherein said salt is ammonium stearate.

5. The facer of claim 1 wherein the latex is an acrylic based resin.

6. The facer of claim 1 wherein said filler is a fire retardant agent.

7. The facer of claim 6 wherein said filler is aluminum trihydrate.

8. The facer of claim 1 wherein said fiber mat comprises glass fiber.

9. The facer of claim 8 wherein said fiber mat contains between about 30 and about 46 wt. % fiber.

10. An insulation board having a non-elastic core and having on at least one surface thereof bonded to an uncoated surface of the facer of claim 1.

11. The insulation board of claim 10 wherein said facer is a glass mat surfaced with said cured foam.

12. The insulation board of claim 10 having a thickness of between about 0.2 and about 4 inches.

13. The insulation board of claim 10 wherein said cured foam of said facer has a density of between about 0.1 and about 0.4 g./cc.

14. A facer-reinforced gypsum board comprising a set gypsum containing core having adhered thereto at least one facer of claim 1.

15. The facer-reinforced gypsum board of claim 14 wherein said gypsum containing core is sandwiched between two facers of claim 1.

16. A tile substrate comprising a board having a cement core and said core adhered to at least one facer of claim 1.