Facer for insulation boards and other construction boards

• US 8,277,931 B1
• Filed: 06/15/2010
• Issued: 10/02/2012
• Est. Priority Date: 09/19/2005
• Status: Active Grant

• Current Assignee: BMIC LLC
• Original Assignee: Building Materials Investment Corporation (Standard Industries Holdings, Inc.)
• Inventors: Kumar, Ajay
• Primary Examiner(s): Ahmed, Sheeba
• Application Number:
  US12/815,483
• Time in Patent Office: 840 Days
• Field of Search: None
• US Class Current: 428/220
• CPC Class Codes: B32B 13/12 of synthetic resin
• CPC Class Codes: B32B 2038/0028 Stretching, elongating
• CPC Class Codes: B32B 2038/166 Removing moisture
• CPC Class Codes: B32B 2307/5825 Tear resistant
• CPC Class Codes: B32B 2307/724 Permeability to gases, adsorption
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2309/105 Thickness
• CPC Class Codes: B32B 2315/085 Glass fiber cloth or fabric
• CPC Class Codes: B32B 2315/18 Plaster
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: B32B 38/0032 increasing porosity B32B38/04 takes precedence
• CPC Class Codes: Y10T 428/249982 With component specified as adhesive or bonding agent
• CPC Class Codes: Y10T 428/249991 Synthetic resin or natural rubbers
• CPC Class Codes: Y10T 428/26 Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
• CPC Class Codes: Y10T 428/31504 Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/31551 Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
• CPC Class Codes: Y10T 428/31616 Next to polyester [e.g., alkyd]
• CPC Class Codes: Y10T 428/31623 Next to polyamide or polyimide
• CPC Class Codes: Y10T 428/31645 : Next to addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31739 : Nylon type
• CPC Class Codes: Y10T 428/31743 : Next to addition polymer from unsaturated monomer[s]
• CPC Class Codes: Y10T 428/31855 : Of addition polymer from unsaturated monomers

Abstract

The subject invention relates to a facer which is comprised of a breathable film and a glass mat, wherein the breathable film and the glass mat are bonded together with an adhesive, wherein the breathable film is comprised of a breathable polymeric material selected from the group consisting of polyolefins, nylons, polyesters, and thermoplastic elastomers, and wherein the facer is water resistant. The facers of this invention can be employed in manufacturing construction board, such as polyisocyanurate boards, polystyrene boards, or gypsum boards. The present invention accordingly more specifically discloses a construction board which is comprised of a rigid sheet and a facer, wherein the facer is bonded to at least one side of said rigid sheet, wherein the rigid sheet is comprised of a member selected from the group consisting of gypsum, blown polystyrene, and polyisocyanurate, wherein the facer is comprised of a breathable polymeric material selected from the group consisting of polyolefins, nylons, polyesters, and thermoplastic elastomers, wherein the breathable polymeric material is bonded to another substrate, such as a glass mat with an adhesive, and wherein the facer is water resistant.

Claims

1. A construction board which is comprised of a rigid sheet and a facer, wherein the facer is bonded to at least one side of said rigid sheet, wherein the rigid sheet is comprised of polyisocyanurate, wherein the facer is comprised of a breathable film and a glass mat, wherein the breathable film and the glass mat are bonded together with an adhesive, wherein the breathable film is comprised of a polymeric material selected from the group consisting of polyolefins, nylons, polyesters, and thermoplastic elastomers, wherein the glass mat is porous, and wherein the facer is water resistant.

2. A construction board as specified in claim 1 wherein the rigid sheet is reinforced with a fiberglass mesh.

3. A construction board as specified in claim 1 wherein the facer is bonded to the rigid sheet with an adhesive.

4. A construction board as specified in claim 3 wherein the adhesive is a breathable adhesive.

5. A construction board as specified in claim 3 wherein the adhesive is applied to only a portion of the surface area of the facer.

6. A construction board as specified in claim 1 wherein the polymeric material is a breathable nylon.

7. A construction board as specified in claim 1 wherein the polymeric material is a breathable thermoplastic elastomer.

8. A construction board as specified in claim 1 wherein the breathable film is a microporous stretched film which is comprised of two incompatible polymers.

9. A construction board as specified in claim 1 wherein the breathable film is 0.5 mils to 5 mils thick.

10. A construction board as specified in claim 1 wherein the breathable film is 0.9 mils to 1.2 mils thick.

11. A construction board as specified in claim 1 wherein the breathable film is a monolithic membrane which is comprised of a thermoplastic elastomer, wherein the breathable film allows for the transmission of vapors by active diffusion, and wherein the breathable film is a barrier to liquid water.

12. A construction board as specified in claim 1 wherein said facer consists of the breathable film and the glass mat.

13. A construction board as specified in claim 11 wherein said facer consists of the breathable film and the glass mat.