Foamed facer and insulation boards made therefrom

• US 20030032351A1
• Filed: 04/08/2002
• Published: 02/13/2003
• Est. Priority Date: 09/08/1998
• Status: Active Grant

• Current Assignee: Building Materials Investment Corporation (Standard Industries, Inc.)
• Original Assignee: Building Materials Investment Corporation (Standard Industries, Inc.)
• Inventors: Horner, Charles J. Jr., Lichten, Lorin J., Longcor, William K. IV
• Granted Patent: US 6,774,071 B2
• Time in Patent Office: Days
• US Class Current: 442/76
• 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 having on at least one surface thereof 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 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 sheet of the facer of claim 1.

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

16. A tile substrate comprising a cement core having adhered thereto at least one sheet of the facer of claim 1.