# US 10,480,183 B2 · Method for making fire-resistant foam insulation panels

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- Number: US 10,480,183 B2
- Document ID: US10480183B2
- Status: Granted
- Kind: B2
- Application number: 15/695,318
- Filed: 2017-09-05
- Published: 2017-12-21
- Granted: 2019-11-19
- Earliest claimed: 2017-09-05
- Assignees: Dow Global Technologies LLC
- Applicants: Dow Global Technologies LLC
- Inventors: Luca Lotti; Maurizio Guandalini; Luigi L. Bertucelli; Paolo Golini
- Web page: https://patentgrep.com/patent/US10480183B2

## CPC

- E04B 1/806: {with air or gas pockets included in the slab}
- B29C 44/065: {comprising at least one barrier layer}
- B29C 44/1209: {by impregnating a preformed part, e.g. a porous lining}
- B29C 44/30: Expanding the moulding material between endless belts or rollers {(B29C44/203 takes precedence)}
- B29C 44/326: {Joining the preformed parts, e.g. to make flat or profiled sandwich laminates}
- B32B 5/20: foamed in situ
- B32B 5/245: {another layer next to it being a foam layer}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 5/32: {at least two} layers being foamed {and next to each other}
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 15/043: {of metal (B32B15/01 takes precedence)}
- B32B 15/046: {of foam}
- B32B 15/08: of synthetic resin
- B32B 15/095: comprising polyurethanes
- B32B 15/12: of paper or cardboard
- B32B 15/14: next to a fibrous or filamentary layer
- B32B 15/20: comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)}
- B32B 17/04: bonded with or embedded in a plastic substance
- B32B 27/065: {of foam}
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 29/007: {next to a foam layer}
- B32B 29/02: next to a fibrous or filamentary layer
- B32B 37/1027: {Pressing using at least one press band}
- B32B 37/24: with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate (B32B37/15 takes precedence)
- B32B 38/0004: {Cutting, tearing or severing, e.g. bursting; Cutter details (cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence)}
- B32B 2037/1215: {Hot-melt adhesive}
- B32B 2037/1253: {curable adhesive}
- B32B 2038/0084: {Foaming}
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/046: Synthetic resin
- B32B 2262/101: Glass fibres
- B32B 2262/105: Ceramic fibres
- B32B 2266/0278: Polyurethane
- B32B 2305/10: Fibres of continuous length
- B32B 2307/304: Insulating
- B32B 2307/718: Weight, e.g. weight per square meter
- B32B 2307/72: Density
- B32B 2307/7265: Non-permeable
- B32B 2309/105: Thickness
- B32B 2311/00: Metals, their alloys or their compounds
- B32B 2315/085: Glass fiber cloth or fabric
- B32B 2419/00: Buildings or parts thereof
- B32B 2419/06: Roofs, roof membranes
- B32B 2605/12: Ships
- B32B 2607/00: Walls, panels
- Y10T 428/24999: Inorganic
- E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001})
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A continuous process for preparing insulation panels having thick (0.2 mm to 1 mm) metal facing panels and a fiber-reinforced polymer foam core is disclosed. In the process, a bottom metal facing panel is continuously supplied. A mat of reinforcing fibers and a foamable resin composition are applied to the bottom facing panel. A flexible barrier layer is applied atop the foamable resin composition, and the assembly is passed through nip rolls to compress the assembly and force the resin composition into the fiber mat. An adhesive layer and top metallic facing layer are then applied on top of the flexible barrier layer, and the resulting assembly is gauged and cured by passing it through a double band laminator.

## Claims

### Claim 1

An insulation panel comprising the following layers: a bottom metallic facing sheet 2 that includes a metal layer having a thickness of 0.2 to 1.0 mm; a polymeric foam layer 21 reinforced through at least a portion of its thickness with a fiber mat 10, said polymeric foam layer 21 being adhered directly or indirectly to the bottom metallic sheet 2; a layer of a flexible barrier material 5 adhered to the fiber-reinforced polymeric foam layer 21; an adhesive layer 4 adhered to the flexible barrier material 5 and a top metallic facing sheet 1 having a thickness of 0.2 to 1.0 mm adhered to the layer of flexible barrier material 5 by the adhesive layer 4, where the flexible barrier material 5 is a layer of mineral wool bonded on one or both sides to a non-porous paper layer.

### Claim 2 (depends on 1)

The insulation panel of claim 1, wherein fiber mat 10 has a weight of 20 to 80 g/m2.

### Claim 3

The insulation panel of 2, wherein fiber mat 10 is a mat of glass fibers.

### Claim 4 (depends on 3)

The insulation panel of claim 3, wherein the layer of flexible barrier material 5 has a thickness of 20 to 100 mm.

### Claim 5 (depends on 3)

The insulation panel of claim 3, wherein top metallic facing sheet 1 is steel and the metal layer of bottom metallic facing sheet 2 is steel.

### Claim 6 (depends on 3)

The insulation panel of claim 3, further comprising a layer of adhesive 6 between bottom metallic sheet 2 and polymeric foam layer 21.

### Claim 7 (depends on 3)

The insulation panel of claim 3, wherein polymeric foam layer 21 has a thickness of 20 to 240 mm.

### Claim 8 (depends on 3)

The insulation panel of claim 3, which has a thickness of 25 to 250 mm.